GOLF CLUB HEAD WITH MULTI-COMPONENT CONTRUCTION

Abstract

A golf club head with a multi-component construction. The golf club head can include one or more components such as inserts, panels, plates, or body members that fasten to one another to form a club head body or that fasten to a club head body. The club head can include one or more components that snap-fit into a club head body. An insert can be made entirely or partially of plastic.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 61/513,509, filed Jul. 29, 2011, the contents of which are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

This application generally relates to golf club heads, particularly golf club heads with multi-component constructions.

BACKGROUND OF THE INVENTION

Historically, an engineer will design a golf club in way that seeks to optimize multiple properties of the finished club. The engineer will chose a shape and size for a club head based on aerodynamics, PGA rules, manufacturing capabilities, and consumer preferences. Within a club head, the engineer will design a mass distribution that provides an acceptable overall compromise of moment of inertia, center of gravity, and weight for the variety of customers who may purchase the club. Once the structure of the club head is designed, it will be finished with colors, surface treatments, logos, and trim in hopes that wide range of people will find the club head attractive. Sometimes a golf company will offer a club in two or a few different finishes and trim levels, in hopes of appealing to more golfers.

Because a number of properties of a club head are influenced by mass distribution and materials, designing a golf club has traditionally been a one-size-fits-all exercise. While some clubs are offered with adjustable weight members or shafts, many properties such as mass distribution, color, aerodynamics, and turf interaction reflect a lowest-common-denominator design paradigm. To offer consumers variety in these properties, golf companies generally must design an entirely new club.

SUMMARY

The invention provides a club head with one or more components that can be easily attached together or to a body member to form a playable club. Components of the invention are separable and re-coupleable and further may be interchangeable. In some embodiments, components may be assembled without the use of adhesives, screws, and/or welding. Multi-component club construction allows a golf company to provide personalized clubs. Each club can be made to appeal to an individual golfer, and the qualities of the club can rise to meet the individual golfer's highest standards, rather than reflecting the lowest-common-denominator found in mass-produced clubs.

Further, the invention offers club heads that may include weight elements that can be removed and replaced. Such weight elements can include specialized tool-mating surfaces and can be used additionally as a convenient assembly mechanism for the interchangeable components.

Another aspect of at least one of the embodiments described herein includes the realization that it would be advantageous to have a club head with a removable insert panels that include materials of different weights and densities so that different panels can be interchanged to distribute mass differently. This allows weight to be distributed within a club head according to a golfer's individual desires.

In certain aspects, the invention provides a club head in which a body member has an opening for a crown insert and an attachment feature (such as a flange) with a crown insert attached there. The crown insert can be a lightweight material (e.g., plastic). In some embodiments, a crown insert is divided by strut-like divider elements, which can modulate the club head physics properties. For example, the dividers may be flexible, non-plastic ribs that divide the crown insert into four plastic sections.

In some embodiments, a club includes a releasably attached weight member that can be added or interchanged with one another to adjust the club head weight, center of gravity, moment of inertia, or a combination thereof. The weight members may have threaded posts that can be screwed into corresponding threaded holes in the club head.

In certain aspects, the invention provides a club head having a body with an opening to receive an insert panel. An attachment feature (such as a flange) at the opening presents a surface for attaching the insert panel. The surface may optionally have holes on or through it. The holes can increase surface area and thus increase bonding strength of an adhesive used to attach the insert. Alternatively, the insert may have a plurality of protrusions to extend through the holes for attachment (e.g., posts that exhibit a tight press-fit; barbed posts; threaded posts to receive a nut element; etc.). A gasket may be positioned at the flange to dampen vibration or modulate weight.

In some embodiments, the insert is attached to the body by a snap-fit assembly, without the use of adhesives or welding. For example, the snap-fit assembly can include cantilevers with protruding tips and a recess corresponding to each tip (e.g., cantilevers on body member and recesses on insert, or vice versa). In some embodiments, the snap-fit assembly includes a collar adapted to be swaged onto a post for attachment and unscrewed with a wrench for removal.

Different inserts can be provided as a set, or as a variety of individual items to be purchased at a store, thus allowing a golfer to customize their club.

In certain aspects, the invention provides golf club head in which a body has a striking face, a heel-side skirt portion, a toe-side skirt portion, and a hosel. Further, a shaft-mounting structure within the body member couples a shaft through the hosel which is fastened in place via a shaft bolt. The club head further has a sole plate or sole insert that is fastened in place at least in part by the shaft bolt. In some embodiments, removing the shaft bolt with a tool allows the sole insert to be manually separated from the club head with no other tools.

In certain aspects, the invention provides golf club head in which a body has a strike face area, a hosel, and an opening with a perimeter. A weight member is releasably attached to the body and an insert panel is releasably held in place over the opening at least in part by the weight member. There may further be a flange disposed at the perimeter of the opening. The insert panel may further include a hole through which a portion of the weight member extends when attached to the body member and an attachment feature spaced away from the hole for coupling to the body member.

In other aspects, the invention provides a set of inserts for customizing a golf club. The set includes at least two insert panels. They are similarly shaped around their perimeters, so that they can be interchangeably mated to a golf club. They can differ in appearance (i.e., color). In some embodiments they have different shapes across their surfaces, for example, to modulate and tune a club head's aerodynamics.

Inserts, panels, plates, body members, and components according to the invention can be opaque, translucent, or transparent. They can be attached to one another or to club heads through the use of barbed posts, adhesive, protruding bosses for coupling via a shaft screw, recesses for receiving a protruding tip of a cantilever, and swage-on/twist-off fastening mechanisms as discussed herein.

Further, in accordance with an embodiment, a golf club head can comprise a body member comprising at least one opening for receiving a crown insert, the body member comprising at least one body attachment feature for attaching the body member to the crown insert, and a crown insert attached to the body member, a majority of the crown insert comprised of plastic, the crown insert comprising at least one crown attachment feature for attaching the crown insert to the body member, the crown insert comprising at least one divider element separating the crown insert into a plurality of plastic portions.

In accordance with another embodiment, a golf club head can comprise a body member comprising at least one opening for receiving a crown insert, the body member comprising at least one body attachment feature for attaching the body member to the crown insert, the at least one body attachment feature comprising a plurality of openings on either a mounting surface of the body member or a plurality of openings on a gasket member connected to the body member, and a crown insert attached to the body member, the crown insert comprising at least one crown attachment feature for attaching the crown insert to the body member, the at least one crown attachment feature comprising a plurality of post-like structures configured to be received within the plurality of openings.

In accordance with another embodiment, a golf club head can comprise a body member comprising at least one opening for receiving a sole insert, the body member comprising at least one body attachment feature for attaching the body member to the sole insert, the at least one body attachment feature comprising a first attachment flange having an angled cross-sectional profile, a sole insert attached to the body member, the sole insert comprising at least one sole attachment feature for attaching the sole insert to the body member, the at least one sole attachment feature comprising a second attachment flange configured to contact the first attachment flange, wherein the sole insert is configured to be attached to the body member by a snap-fit configuration, without the use of adhesives or welding.

In some aspects, the invention provides a golf club head in which the body has an opening shaped to connect to an insert component. There is a bore through the hosel and sole so that a removable shaft can be connected to the club head. The insert is fastened into place by fastening a shaft to the assembled club head, which, for example, compresses the insert to the body due to a compressive force between a ferrule fixed on the shaft and a shaft screw extending into the shaft from the sole of the club head.

In other aspects, the invention provides a golf club head in which two components are assembled along an attachment perimeter. At least part of the attachment perimeter is wavy (for example, when projected onto a plane, the attachment perimeter appears as a line having at least three inflexion points, optionally four or five, that can be connected within the plane by an arc having no inflexion points).

In other aspects, the invention provides a multi-component golf club head in which one component is malleable, for example, made of rubber. The malleable or deformable component can be mated with, and fixed to, a feature on another component (e.g., the club head body) to form an assembled club head. In this way, the malleable component can provide a flap, for example, to act as a cover for a port or hole. In some embodiments the malleable component mates to a raised, rigid boss. The malleable material can include rubber, PVC, silicon, or a similar material.

In other aspects, the invention provides a multi-component golf club head in which one component fastens to another through the use of a cam. For example, the cam may be part of a lever, which can function as a handle to release the cam, thereby releasing one component from another. In some embodiments, releasing the cam releases an insert from a corresponding hole on a club head body. The cam member may be provided with a tool engagement surface. The cam may be disposed in a mechanism that drives one or more engagement hooks to hook around a part of the club head to hold a component in place.

In other aspects, the invention provides a golf club head having an insert adapted to be coupled to an opening, or cutaway, in the club head body. The insert may be fastened to a shaft of the golf club. While the insert is visually mated to the club head body around an attachment perimeter, by being fastened to the shaft directly (i.e., while the club head body is also fastened to the shaft directly), the club head exhibits very appealing playability characteristics for a multi-component club head. For example, in some embodiments, energy from the impact of a shot is transmitted through the shaft and does not interfere with the coupling of the insert to the body.

In certain aspects, the invention provides a method of providing a customized golf club head by receiving a consumer's selection of an option and storing the selection in a tangible, non-transitory memory. A digital file with the information about a club head including the selected option is created by a computer processor coupled to the memory. The information is transferred to a production site and a customized club head including the selected option is produced. For example, a consumer's selected option can be a choice of insert to be provided with the club head. In a related aspect, the invention provides a system for providing a customized golf club. The system includes a computer with a tangible, non-transitory memory coupled to a processor. The system is used to receive a consumer's selection of an option and store the selection in the memory, then create a digital file including information about a club head including the selected option. Devices of the system transfer the information to a production site and write a file comprising billing and shipping data for use in a sale transaction.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present embodiments will become more apparent upon reading the following detailed description and with reference to the accompanying drawings of the embodiments, in which:

FIG. 1 is a bottom perspective view of a golf club head in accordance with at least one embodiment;

FIG. 2 is a cross-sectional view, taken along line 2-2, of the golf club head of FIG. 1;

FIG. 3 is a top perspective view of the golf club head of FIG. 1, with a crown portion removed;

FIG. 4 is a cross-sectional view, taken along line 4-4 of FIG. 3, of the golf club body member of FIG. 1, with the crown member attached to the body member;

FIG. 5 is a top plan view of a plastic crown insert in accordance with at least one embodiment;

FIG. 6 is a top plan view of an alternative embodiment of the crown insert of FIG. 5; and

FIGS. 7 and 8 are embodiments of detail C, shown in FIG. 4; and

FIG. 9 is a partial view of a club head and insert according to an embodiment.

FIG. 10 shows a club with sole plate.

FIG. 11 is a bottom view of a club head with detachable sole plate.

FIG. 12 shows a sole plate according to certain embodiments.

FIG. 13 is a cross section across the line in FIG. 11.

FIG. 14 illustrates a detachable sole plate fixed into a place with a weight member.

FIG. 15 shows a weight member for fixing a sole plate into place.

FIG. 16 shows a club head configured to receive a sole plate.

FIG. 17 shows a club head with slotted flange and deformable crown panel.

FIG. 18 shows a club head with slotted flange.

FIG. 19 shows insertion of a deformable crown panel into slotted flange.

FIG. 20 shows a club head with flange with holes.

FIG. 21 shows a crown panel with barbed posts for insertion into holes in a flange.

FIG. 22 shows a cross-sectional view of barbed posts and flange with holes.

FIG. 23 is a side view of a club head and crown panel with barbed posts.

FIG. 24 shows a club head with button tabs and attachable crown panel.

FIG. 25 shows the club head and panel in FIG. 24 assembled.

FIG. 26 shows a club head and sole plate with pre-attached adhesive strips.

FIG. 27 shows a club head with cage structure and attachable crown panel.

FIG. 28 is a cross-sectional view of a club head assembled with a rapid fastening system.

FIG. 29 illustrates a method of rapidly fastening a sole plate to a club head.

FIG. 30 shows a threaded post for use in a rapid fastening system.

FIG. 31 shows a barbed post for attachment to a hole.

FIGS. 32A-32C illustrates a mechanism of a rapid fastening system.

FIG. 33 shows a hosel/face member and a body member.

FIG. 34 shows the components of FIG. 33 assembled with a rapid fastening system.

FIG. 35 shows a club head with voids and a translucent insert panel.

FIG. 36 shows an opaque insert panel for a club head with voids.

FIG. 37 shows a club head assembled with an insert panel.

FIG. 38 shows a face member and body member with corresponding threaded portions.

FIG. 39 is a top view of a face member and body member with threaded portions.

FIG. 40 shows a club head body with closeable strap and crown panel with groove.

FIG. 41 shows an assembled club head with crown panel strapped to body.

FIG. 42 is a top view of the club head shown in FIG. 41.

FIG. 43 shows a club head face member with cantilevered posts.

FIG. 44 shows a tool for separating a cantilevered attachment point.

FIG. 45 shows a club head body member with recesses for receiving cantilever tips.

FIGS. 46-49 show configurations of cantilevered posts and recesses.

FIGS. 50A-50C show a club head with component with cam mechanism.

FIG. 51 is a detail view of the cam mechanism of FIGS. 50A-50C.

FIG. 52 illustrates radii around a cam axis.

FIGS. 53A-53D show a club head with cam and engagement hooks.

FIGS. 54A-54B show an engagement member for engagement hooks.

FIGS. 55A-55B show a component coupling system.

FIG. 56 shows a shaft collar for using a coupling system.

FIGS. 57 and 58A-58C show a club head with crown component.

FIG. 59 shows a club head with crown component.

FIG. 60 shows a snap-fit catch for a component.

FIG. 61 shows a club head with a flap component.

FIGS. 62A and 62B show use of a flap component to fasten a club head component.

FIG. 63 shows a club head with removable sole component with magnets.

FIG. 64 is a top view of a boss member with magnet therein.

FIG. 65 is a cross-sectional view of a set of magnet bosses.

FIG. 66 shows an insert panel.

FIG. 67 shows a club head body.

FIG. 68 shows magnets coupling an insert to a club head body.

FIG. 69 shows a display for receiving option selections.

FIG. 70 is a block diagram of a method for providing a customized club head or golf club according to certain embodiments.

FIG. 71 is a block diagram of a system for providing a customized club head or golf club.

DETAILED DESCRIPTION

The present application is directed to golf club heads, and particularly to golf club heads with multi-component structures. While the embodiments disclosed herein include club heads for wood-type clubs, it is contemplated that one or more of the concepts described herein can further be used for other types of club heads, including but not limited to irons and putters.

With reference to FIGS. 1-4, a golf club head 10 can comprise a ball striking face 12, a crown 14, a sole 16, and a hosel 18. The golf club 10 can further comprise a body member 20, a face insert 22, at least one sole insert 24, and at least one crown insert 26. In some embodiments, the body member 20 can comprise a metallic member that includes a plurality of openings for receiving the face insert 22, sole insert 24, and/or crown insert 26. In some embodiments, the body member 20 can be comprised, at least in part, of a 6-4 titanium alloy, though other types of material are also possible. As illustrated in FIGS. 1-4, in some embodiments the body member 20 can comprise a portion or portions of the ball striking face 12, crown 14, and/or sole 16.

With reference to FIG. 3, in some embodiments the hosel 18 can comprise a sleeve 28 that permits interchangeability and/or adjustability of a golf club shaft. In some embodiments the sleeve 28 can be comprised of 6062 aluminum, though other types of materials are also possible. In some embodiments, the sleeve 28 can be adjusted so as to adjust the lie angle of the club head 10. Other types of material and/or structure can also be used for the sleeve 28. U.S. Pat. No. 7,789,766, the entire contents of which are incorporated by reference herein, describes various adjustability features of a sleeve similar to sleeve 28.

With reference to FIG. 1, in some embodiments the hosel 18 can also comprise a hosel sleeve screw 30 configured to releasably attach one or more components of the hosel 18 to the club head 10. The screw 30 can be comprised, for example, of 304 stainless steel produced using a traditional screw machine with a T20 head, though other types of materials and screws are also possible. Additionally, other types of fasteners besides screws can be utilized. In some embodiments, the screw 30 can be inserted within a recess 31 in the body member 20.

With continued reference to FIGS. 2 and 4, the face insert 22 can comprise at least a majority, for example by volume and/or mass, of the ball striking face 12. In some embodiments, the face insert 22 can form approximately 60 percent of the volume and/or mass of the ball striking face 12. In some embodiments, the face insert 22 can form approximately 70 percent of the volume and/or mass of the ball striking face 12. In some embodiments, the face insert 22 can form approximately 80 percent of the volume and/or mass of the ball striking face 12.

The face insert 22 can be comprised of metal, or other suitable material. In some embodiments the face insert 22 can be comprised of the same material as the body member 20. In some embodiments the face insert 22 can be comprised of 6-4 titanium. In some embodiments the face insert 22 can be comprised of more than one type of material and/or more than one layer of material.

In some embodiments, the face insert 22 and/or ball striking face 12 can transition into the crown 14 and sole 16 at a transition point or area. The transition point or area can be a location where a line drawn perpendicular to a tangent line extending along the surface of the club head 10 at the transition point or area forms an approximately 45 degree angle relative to a vertical plane passing through the club head 10.

With continued reference to FIGS. 2 and 4, in some embodiments the crown insert 26 can comprise at least a majority, for example by volume and/or weight, of the crown 14. In some embodiments, the face insert 22 can form approximately 60 percent of the volume and/or mass of the ball striking face 12. In some embodiments, the face insert 22 can form approximately 70 percent of the volume and/or mass of the ball striking face 12. In some embodiments, the face insert 22 can form approximately 80 percent of the volume and/or mass of the ball striking face 12.

The crown insert 26 can be comprised of composite, reinforced plastic, thermoplastics, or other suitable material. With reference to FIG. 5, in some embodiments the crown insert 26 can be comprised entirely of injection molded material. In some embodiments, the insert 26 can be comprised of single or multi-density metallic or non-metallic material.

In other embodiments, and with reference for example to FIG. 6, the crown insert 26 can have one or more portions 38 that are comprised of plastic, along with one or more flexible divider elements 40 that connect the portions 38 together. In some embodiments, a majority of the crown insert 26 is a thermoset or thermoplastic material, which may optionally be reinforced with secondary fibers, such as carbon, glass, wood, plant or metal such as, for example, a plastic. In some embodiments, the portions 38 can be interchangeable. The divider elements 40 can be comprised, for example, of any metallic or non-metallic material desirably having a density less than that of the body member 20. In some embodiments, the divider elements 40 can be bonded with the remaining portions 38 of the crown insert 26. In some embodiments the divider elements 40 can be formed integrally with the remaining portions 38. In some embodiments, the divider elements 40 can divide the crown insert 26 into four portions 38, though other numbers of portions are also possible. The divider elements 40, along with the plastic portions 38, can give the crown insert 26 flexibility and reduced weight as compared with crown inserts made of metal or carbon fiber. The added flexibility can inhibit the plastic material of crown insert 26 from cracking or fracturing. In some embodiments, if the flexibility is too great, and negatively affects the sound/tuning of the club head 10, additional measures can be taken to reinforce the club head 10 and/or to create better sound qualities. For example, a gasket can be added between the crown insert 26 and the body member 20, or material such as latex can be added between the crown insert 26 and the body member 20, to act as a sound barrier. In some embodiments, a support member can extend generally from the sole 16 to the crown 14 can be added to the club head 10.

In some embodiments, the club head 10 can have a density ratio between the body member 20 and an insert. For example, in some embodiments the ratio of the density of the body member 20 to the crown insert 26 can be 1.5. In some embodiments, the density ratio between the body member 20 and one of the inserts can be approximately 2.0, 2.5, 3.0, 2.5, 4.0, or higher than 4.0. Other density ratios are also possible.

Overall, the use of plastic (such as, for example, polyurethanes, polyesters, epoxy resins, phenolic resins, and carbon composites) in the crown insert 26 can, at least in some embodiments, not only reduce weight but also facilitate a generally transparent, or at least partially transparent, club head 10. Transparency can allow a user to view whether material has accumulated inside the club, and/or whether the club head 10 is damaged or showing signs of wear on the inside. In some embodiments, the crown insert 26 can be translucent. In some embodiments the crown insert 26 can be comprised of a photochromic material. The plastic can reduce weight in the crown 314, thus allowing the weight that otherwise would been located in the crown 314 to be optimally redistributed to other areas of the club head 310 to optimize a location of a center of gravity, for example, or optimize moments of inertia in the club head 310.

With continued reference to FIGS. 2-4, the crown insert 26 and/or body member 20 can comprise at least one mounting feature 42. The mounting features 42 can be used to attach the crown insert 26 to the body member 20 or other component of the club head 10. For example, with reference to FIG. 4, in some embodiments the mounting features 42 can comprise attachment flanges, permitting the crown insert 26 to be adhesively attached, for example, or welded, to the body member 20. In some embodiments, mounting features can comprise non-threaded attachments that clamp and unclamp with the push of a finger, hand, or tool. The mounting features can include one-touch fasteners and may have internal springs. A press-fit or snap-fit assembly can be used. In some embodiments, a tool can be used to release an insert, such as the crown insert, to replace it with a different crown insert.

With reference to FIGS. 3, 4, 7 and 8, in some embodiments the mounting features 42 on the crown insert 26 can comprise post-like structures 44 that are configured to be received within corresponding mounting features 42 on the body member 20. The corresponding mounting features 42 on the body member 20 can comprise, for example, openings 46 on a mounting surface 48 of the body member 20. In some embodiments, and with reference to FIG. 8, a gasket member 47 can be placed between the body member 20 and crown insert 26. For example, the gasket member 47 can be adhesively attached to the body member 20. In some embodiments, instead of the body member 20 having openings 46, the gasket member 47 instead can include the openings 46. Alternatively, in other embodiments both the gasket member 47 and body member 20 can include openings, and the post-like structures 44 can be inserted through the gasket member 47 and into the body member 20.

With continued reference to FIGS. 3, 4, 7, and 8, the post-like structures 44 and openings 46 can be spaced around the club head 10, such that the crown insert 26 is secured firmly to the body member 20 in a plurality of locations. For example, the mounting surface 48 can include six openings 46 spaced generally equally around the club head 10, and the crown insert 26 can include six post-like structures 44 that are configured to be received within the six openings 46. In some embodiments, the post-like structures 44 can press or snap-fit into the openings 46, and the crown insert 26 can be held in place without the use of any additional adhesive, welding, etc. In some embodiments, additional adhesive can be used, for example between an outer edge of the crown insert 26 and the mounting surface 48. In some embodiments, the crown insert 26 can be mounted to the mounting surface 48 without the use of post-like structures 44 or openings 46. For example, in some embodiments the crown insert 26 can be attached purely by adhesives, welding, mechanical attachment, etc.

With reference to FIGS. 1, 2 and 4, in some embodiments the sole insert 24 can comprise at least a majority, for example by volume, of the sole 16. The sole insert 24 can include composite, plastic, or any other suitable material. In some embodiments, sole insert 24 is made of injection molded plastic. Further, sole insert 24 may have secondary coatings or be co-molded to other materials. Co-molded materials and secondary coatings can include ceramics, anodizing, or similar. In some embodiments, a secondary coating or co-molded material includes a low-friction polymer. For example, sole insert 24 may have a hard-anodized coating infused with a low-friction polymer such as a fluorinated polymer (e.g., poly-tetrafluoroethelyne (PTFE), sold under the trademark TEFLON by DuPont). Suitable coatings are discussed in U.S. Pub. 2011/0118057, the contents of which are hereby incorporated by reference in their entirety for all purposes.

Sole insert 24 can have a variety of shapes and sizes. For example, the sole insert 24 can have an oblong and/or generally hourglass-like shape, such as that shown in FIG. 1. Other shapes and sizes are also possible. As with the crown insert 26, the sole insert 24 can also be comprised of a material that is lightweight, and/or less dense, than that of the body member 20, so that weight can be redistributed as desired to other areas of the club head 10, and a center of gravity of the club head 10 can for example be pushed towards the back and heel side of the club head 10, and/or moments of inertia can be optimized. In some embodiments, a movement of weight can advantageously increase a moment of inertia of the club head 10, causing reduced unwanted twisting or movement of the club head 10 upon impact with a golf ball.

In some embodiments, there can be more than one sole insert 24. In some embodiments, a sole insert 24 can have a divider, similar to at least one of the embodiments of the crown insert described herein.

With continued reference to FIGS. 1, 2, and 4, the sole insert 24 can comprise at least one mounting feature 42. The mounting features 42 can be used to attach the sole insert 24 to the body member 20 or other component of the club head 10. With reference to FIG. 2, in some embodiments the mounting features 42 of the sole insert 24 and body member 20 can comprise one or more attachment flanges. For example, the sole insert 24 can include a first attachment flange 50 that extends inwardly from the sole insert 24. In some embodiments, the first attachment flange 50 can extend at a right angle relative to a surface of the sole insert 24. The attachment flange 50 can be configured to contact and/or mate with a corresponding attachment flange 52 on the body member 20. The attachment flange 52 can have a bent profile, for example, and extend inwardly from the body member 20 (e.g. towards an interior volume of the club head 10).

In some embodiments, the sole insert 24, and/or other inserts on the club head, can be configured to snap-fit into the body member 20. For example, in some embodiments, at least one surface of attachment flange 50 can contact and press against at least one surface of the attachment flange 52 of the body member 20, helping to hold the sole insert 24 in place relative to the body member 20. The insert 24 can be held in place by friction. In some embodiments the sole insert 24 can include an additional flange 54, which contacts a flange 56 on the body member 20. The flanges 54 and 56 can also be configured to contact one another, and/or snap-fit in place or be attached by adhesive, welding, etc. In some embodiments, the body member 20 can include a flange or flanges that are biased in a first direction, such that when an insert is positioned within the club head 10, the flanges are forced away from the first direction towards a second direction, the flanges pressing back against the insert towards the first direction to hold the insert in place again once the insert has been attached. For example, in some embodiments the flange 52 can be biased in a first direction towards the back end of the club head, and pushed towards a second direction towards the front of the club head when the sole insert 24 is attached. In some embodiments, the body member 20 can include flanges with ends that are initially biased towards one another, and when an insert is attached, the ends are pressed away from one another, the force of the ends of the flanges holding the insert in place. In some embodiments, adhesive, welding, and/or mechanical structures can be used to help hold one or more inserts (e.g. the sole insert 24) in place within the body member 20.

In certain embodiments, either crown insert, sole insert, any other insert such as a face insert or skirt insert (or combination thereof), or any other component is fastened to form a playable club by a mounting feature that uses a threaded mechanism. For example, a mounting feature may include a screw well such as, for example, those described in U.S. Pub. 2011/0111885, the contents of which are hereby incorporated by reference in their entirety for all purposes. Further, an insert may be fastened into place by a screw through another portion of a club head. Threaded elements are discussed in U.S. Pat. No. 8,033,930; U.S. Pat. No. 7,771,290; U.S. Pat. No. 5,776,011; and U.S. Pat. No. 5,429,365, the contents of which are hereby incorporated by reference in their entirety for all purposes.

In some embodiments, one or more inserts, such as sole insert and/or crown insert 24, 26 can be configured to have a size larger than that of a corresponding opening on the body member 20. When the sole insert and/or crown insert 24, 26 is inserted into the opening in the body member 20, the sole insert and/or crown insert 24, 26 can flex initially, and/or the body member 20 can flex initially, and the sole insert and/or crown insert 24, 26 can be held in place frictionally once positioned inside the opening. In some embodiments, the sole insert and/or crown insert 24, 26 can force one or more flanges 50 to act as a spring mechanism, applying a force on the sole insert and/or crown insert to hold the sole insert and/or crown insert 24, 26 in place within the body member 20.

Other snap-fit constructions can also be used. For example, and with reference to FIG. 9, in some embodiments a body member 20 of a club head can include one or more recesses, channels, openings, or other structures 58 along the inside or outside of the club head configured to receive an attachment flange 60 on an insert 62, and to temporarily lock the attachment flanges 60 and the insert 62 into place within the club head. The insert 62 can be removed, for example, by pressing on one or more areas of the insert 62, such as the outside edges of the insert.

In some embodiments, screws, clamps, or other fasteners can be used to connect, remove, and/or replace the inserts. In some embodiments, adhesive can be used to help hold an insert or inserts in place that will not be replaced.

In certain embodiments, two club head components can be joined, or a component can be joined to a body part, by an assembly method such as staking, ultra-sonic welding, or heat staking. For example, The seams as shown in FIG. 4 provide surfaces that can be attached by these methods. In certain embodiments, components are assembled by heat staking. FIG. 29 illustrates one way in which an assembly tool can access seams for assembly by heat staking.

Heat staking is a means of locking club head components together. In general, one of the parts to be assembled is designed to include a plastic post or tab which can be inserted through a hole or aperture in another part and then permanently and inelastically deformed by the generation or application of heat by some tool surface which effects plastic deformation. The variables which can be tuned include the characteristics of the particular plastic material employed including its flow and melt temperatures, the nature and characteristics of the tooling employed and the geometries thereof, means by which the tooling may be brought to bear against the plastic elements to be deformed, the choice of method for effecting heating, and the parameters of pressure, time, and heat energy applied.

In one embodiment, a plurality of first thermoplastic components, or heat-stakes, may be located sporadically around the periphery of a component and a second component may comprise a plurality of second thermoplastic components, or encapsulates, comprising receiving holes located in corresponding locations to the heat-stakes of the first automotive component. The heat-stakes may be inserted into the receiving holes and a staking device may be used to heat-treat a leading end of each heat-stake. This use of the staking device results in the deformation of the heated leading end of the heat-stake such that a “mushroom cap” may be formed. The mushroom cap of each heat stake commonly covers the corresponding receiving hole of the encapsulate. This resulting overlap results in the mechanical coupling of the first and second components. The resulting retention force of a heat staking process may be tuned by varying the amount of surface area of the encapsulate contacted by the heat-stake's mushroom cap as well as the composition states of the encapsulate and heat-stake.

A particular advantage of heat stake in club head assembly is that such methods operate well with dissimilar materials. For example, a plastic component with stakes can be fastened to a metal component with receiving holes by heat staking. Heat staking is discussed in more detail in U.S. Pat. No. 6,840,755; U.S. Pat. No. 6,296,470; U.S. Pat. No. 5,871,784; U.S. Pat. No. 4,767,298; and U.S. Pub. 2008/0230948, the contents of each of which are hereby incorporated by reference in their entirety for all purposes.

In certain embodiments, two club head components can be joined, or a component can be joined to a body part, through the use of magnets, discussed in more detail below.

In some embodiments, the club head 10 can include an entire set of different inserts that can be easily removed and replaced. This can facilitate consumer customization of the club head 10. For example, a club head set could include a club head 10 with a body member 20, and a plurality of different thickness, density, weight, and/or transparency crown or sole inserts. A user can select a desired insert or inserts, and quickly and easily attach the desired inserts. Advantageously, in some embodiments the inserts can press-fit or snap-fit into place within the body member 20, for example as described above. The inserts can be interchangeable, and in some embodiments can comprise a kit, the parts of which can be tailored to specific golfer needs. In some embodiments, the customization could include choosing from a plurality of inserts with different indicia, designs, etc., including but not limited to country flags, favorite teams, etc.

With continued reference to FIG. 1, the club head 10 can further include at least one weight member 58. The weight member 58 can removable, and can be inserted into a portion of the body member 20. In some embodiments, addition of a weight member 58 can advantageously permit more weight to be moved towards the heel of the club head 10. In some embodiments, the weight member can have a head 60 that has an outer surface that is generally flush with an outer surface of the body member 20. The weight member 58 can comprise a weight screw, formed for example from tungsten, stainless steel, such as 17-4, aluminum, or other suitable materials. Other types and materials are also possible. In some embodiments, the weight screw head 60 can include one or more tool cavities 62. The tool cavities can be configured to receive a tool, such as a specialized tool, that is configured to remove the weight screw 58. In some embodiments the tool cavities 62 can comprise two separate openings. In some embodiments the tool cavity can comprise a generally star-shaped opening for receiving a correspondingly-shaped tool. Other shapes and types of tool cavities are also possible. In some embodiments the club head 10 can be configured to receive various weight screws 58 of different weight, so that the swing weight of the club head 10 can be altered. For example, in some embodiments the weight screw 58 can be comprised of tungsten, and weigh approximately 10 grams. In some embodiments the weight screw 58 can be comprised of stainless steel, and weight approximately 6 grams. In some embodiments the weight screw 58 can be comprised of aluminum and weight approximately 2 grams. Other materials and weights are also possible. The type and weight of weight screw 58 used in the club head 10 can depend on an overall club head weight, a desired swing weight, a desired location of a center of gravity of the club head 10, and/or a desired moment of inertia of the club head 310. For example, the club head 10 can be designed, and a weight screw 58 can be selected, such that a center of gravity of the club head 10 is located approximately 4 mm rearward from a geometric center point on the face insert 22, and approximately 4 mm above a lowest point on the sole 16 when the club head 10 is at address. Other locations for the center of gravity are also possible.

In some embodiments, the ratio of the weight screw material density to body material density (i.e. between weight screw 58 and body member 20) can be approximately 1.5. In some embodiments the density can be approximately 2.0, 2.5, 3.0, 3.5, 4.0, or higher than 4.0. Other density ratios are also possible.

In some aspects, the invention provides a club head with a removable or interchangeable component, such as a crown panel or sole plate, that is affixed to the a club head body through the use of a mechanism in a club head that also provides other functionality. Through the use of mechanisms that also provide other functionality, it is possible to provide a club head with one, two, three or more separable panels that further include no visible assembly mechanisms (e.g., protruding plastic tabs, recessed holes, etc.) other than the mechanism associated with the other functionality.

FIG. 10 shows club head 64 with insert 62 and FIG. 11 is a bottom view of club head 64. FIG. 12 shows insert 62 having boss 63 and clasp 66. Club head 64 is assembled by positioning clasp 66 on the inside edge of the insert hole in the bottom of the body of club head 64. Insert 62 is then closed, using clasp 66 as a hinge, so that boss 63 comes proximal to repositionable shaft housing 65.

Club head 64 includes housing 65 to receive and mount a repositionable shaft in various dispositions. When a shaft is mounted in a hosel of club head 64, hosel sleeve screw 30 fastens the shaft into place. As shown in FIGS. 10-13, hosel sleeve screw 30 can also serve to fix insert 62 into position. Golf clubs including adjustable mechanisms, or adjustable mechanisms for golf clubs, suitable for operation with the invention, are discussed in U.S. Pub. 2010/0041493; U.S. Pub. 2011/0098128; U.S. Pat. No. 8,057,323, U.S. Pat. No. 1,879,117 and U.S. Pat. No. 3,096,982, incorporated by reference herein in their entirety.

As shown in FIG. 13, when insert 62 is installed in club head 64, clasp 66 is entirely within the club head. Insert 62 is held in place securely by hosel sleeve screw 30, which is associated with other functionality of the club head (e.g., an interchangeable/repositionable shaft).

Further, as shown in FIG. 14, insert 62 can be held in place by one or more of releasable weight component 58. FIG. 15 shows a weight component 58 having two tool cavities 61 and a threaded post 63.

FIG. 16 shows club head 64 configured to receive insert 62 (here, a sole plate). Club head 64 includes boss 67 having a threaded hole to mate with threaded post 63. Club head 64 further includes attachment flange 56 and repositionable shaft housing 65. Insert 62 can be positioned on the base of club head 64 with 66 hooked therein. Weight component 58 and shaft screw 30 can then be tightened (e.g., with a tool), fixing inset 62 there in place. One insight of the invention associated with clubs with most beneficial properties is the dual functionality of a releasable weight component to provide a customizable mass distribution while also providing a mechanism for fastening a separable component to a club head. Separable components are discussed in U.S. Pub. 2011/0294589, the contents of which are hereby incorporated by reference in their entirety for all purposes. Here, the invention provides the ability to finely-tune a club head to correct for a golfer's hook or slice by positioning the weight on a heel side, toe side, or both, through the use of a releasable weight component. Rather than simply adding a mass of weight, the fastening mechanism of the present invention derives most desirable additional utility in unexpected ways by harmonizing the placement of releasable weights used to aid in improving a golfer's shot with the fastening of releasable body components.

In some aspects, the invention provides club heads with separable components that can be attached or removed without the use of tools.

FIG. 17 shows a club head 71 with slotted flange 77 and deformable crown panel 75. As shown in FIG. 18, slotted flange can extend around an aperture in a club head, completely or in part. Crown panel 75 is then positioned so that a thin edge 79 is pressed against slotted flange 77, as shown in FIG. 19. Crown panel 75 deforms plastically or elastically (strictly speaking, it is an elastic deformation, which is sometimes referred to as a plastic deformation). As shown in FIG. 19, panel 75 can be bent so that it bows outwards, allowing thin edges 79 to be inserted into slot 76 in slotted flange 77. As panel 75 is released, it tends to return to its original shape such that thin edge 79 fully inserts into slot 76. In some embodiments, it is pushed entirely into place and adjusted by hand.

In some embodiments, a separable component is attached to a club head 81 without tools through the use of one or more barbed posts. FIGS. 20-23 show a tool-less removable panel attachment system. As shown in FIG. 20, club head 81 includes a flange 87 having one or more of hole 83 therethrough. FIG. 21 shows an insert having one or more barbed post 89 positioned and dimensioned to correspond to the holes 83. FIG. 22 shows a detailed cross-sectional view of barbed posts 89 and flange 87 with holes 83. When insert panel 85 is pushed into place, each barbed post 89 pushes through a hole 83. The barbs deform plastically/elastically and retain insert 85 mounted securely on club head 81. FIG. 23 is a side view of club head 81 and crown panel 85 with barbed posts 89 positioned to be attached together.

In certain embodiments, club head 81 is provided for use with one or more disposable inserts 85. Each insert 85 can have a novel or interesting color or pattern. A golfer chooses one that he or she finds pleasing and inserts it into club head 81 through the use of the barbed posts (or any of the other suitable mechanisms such as those described elsewhere herein). When the golfer wishes to remove insert 85, pulling it away from club head 81 snaps all of the barbed posts off, and the insert is set aside. A golfer may use a tool, such as a thin, flat screwdriver, to lift a first edge of insert 85 to aid in removing it.

In certain embodiments, the invention provides a club head with a removable and re-attachable panel through the use of depressable engagement tabs. FIG. 24 shows a club head 91 with four of depressable engagement pad 92 and attachable crown panel 95. Crown panel 95 has four receiving holes 93 dimensioned to correspond to a button portion of the depressable engagement pads 92. When crown panel 95 is pushed onto club head 91, pads 92 deform (e.g., bend inwards) and then snap into place. FIG. 25 shows an assembled club head 91. To remove panel 95, the button portion of pads 92 is depressed and panel 95 is lifted off.

Any suitable number of pads 92 may be included, and in any suitable arrangement.

In some embodiments, a removable or disposable panel is provided to be attached via adhesive. FIG. 26 shows a club head 101 and sole plate 103 with pre-attached adhesive strips 105. Adhesive strips 105 can be located to correspond to flange 107. Alternatively, plate 103 may not include adhesive strips 105, and they can be provided separately (e.g., as double-stick tape). In some embodiments, plate 103 is fastened into place through the use of VHB adhesive tape, wet epoxy, or a combination thereof. Fastening is discussed in U.S. Pub. 2011/0045921, the contents of which are hereby incorporated by reference in their entirety for all purposes.

In various embodiments, providing a club head with a body member and one or more outer panels provides a club designer with opportunities for novel arrangements of material to tune a mass distribution, to enhance strength, to refine sound tuning, or modify coefficient of restitution of a club head. For example, certain embodiments, a panel will be used to cover what would otherwise be one or more holes in a club head body. Where the club head body includes a metal or other heavy material, and the panel includes a plastic, composite, or other lightweight material, this can provide significant weight savings.

FIG. 27 illustrates a club head 111 having a crown panel 115 to cover a cage portion 113 that includes one or more of hole 119a, 119b, . . . etc. Cage portion 113 can be surrounded by lip 117 dimensioned to correspond to an edge of panel 115. It may be found that this construction of a club head provides excellent durability and coefficient of restitution, while allowing for significant mass savings (relative to a club head without holes 119). Furthermore, panel 115 can be customizable or interchangeable. In certain embodiments, panel 115 has adhesive on an inner surface, barbed posts corresponding to holes in club head 111, a thin edge corresponding to a slotted flange on club head 111, or any other suitable attachment mechanism such as those described herein.

In certain embodiments, a club head with a multi component construction makes use of a rapid fastening system such as the bolt assembly sold under the trademark POPBOLT by Emhart Technologies (Shelton, Conn.). FIG. 28 is a cross-sectional view of a club head 121 assembled with a rapid fastening system. As shown in FIG. 28, a panel 125 is mounted to a flange in club head 121. A bolt post member 124 protrudes through a hole in the flange, and a collar 127 is affixed thereto. In certain embodiments, post member 124 is a threaded bolt and collar 127 is a threaded nut.

In some embodiments, post member 124 and collar 127 are components of a rapid fastening system. FIG. 29 illustrates a method of rapidly fastening a sole plate to club head 121. As shown in FIG. 29, post member 124 is provided by a separate bolt. Collar 127 is positioned thereon and tool 129 is used to fasten collar 127 to post member 124. When using a system such as the bolt assembly sold under the trademark POPBOLT, collar 127 is swaged to post member 124. Post member is threaded to begin with and swaging collar 127 to post member 124 causes collar 127 to become threaded. Collar 127 can then be removed through the use of a wrench. Swaging collar 127 to post member 124 is described in FIG. 32.

In certain embodiments, a post member 128 is formed integrally with insert 125 and protrudes from a surface of the insert, as shown in FIG. 30. In some embodiments, a protruding post is a barbed post 89. Insert 125 with barbed post 89 can be used in club head 121, even where club head 121 can also, separately, be used with a rapid fastening system. In some embodiments, club head 121 has a rapid fastening system used to fasten insert 125 in place (e.g., by swaging collar 127). Then, collar 127 is removed with a wrench and insert 125 is removed and set aside. Another insert 125 that includes barbed posts 89 is then fixed to club head 121 using the same holes. By these means, a club head can be customized with a tool (for example, in a pro shop) by one method, but then can be “field stripped” and re-customized out on the course without the benefit of the tool system.

FIGS. 32A-32C illustrate the operation of a rapid fastening system such as the bolt assembly sold under the trademark POPBOLT by Emhart Technologies (Shelton, Conn.). As shown in FIG. 32A, a bolt or post is inserted through a hole (e.g., post 124 protruding from insert 125 is inserted through a hole in a corresponding flange on a club head body). FIG. 32B shows positioning collar 127 over post 124 through the use of tool 129. In certain embodiments, a tool 129 of a rapid fastening system carries collar 127 and positions it over post 124. As illustrated by FIG. 32C, operating a trigger on tool 129 swages collar 127 to post 124 (simultaneously forming a threaded connection). Operating tool 129 also breaks off an excess portion of post 124 and removes it. Tool 129 can then be taken away from the assembly site.

FIG. 33 shows a hosel/face member 131 and a body member 135 adapted to be coupled together with a rapid fastening system. Face member 131 can include one or a number of post member 124, while body 135 has a corresponding number of inset boss 133 dimensioned so that post 124 slides through a hole therein. In certain embodiments, collar 127 is then positioned on post 124 and fastened into place as discussed above and as shown in FIG. 34. Suitable club heads for use with systems of the invention are discussed in U.S. Pat. No. 7,959,522, the contents of which are hereby incorporated by reference in their entirety for all purposes.

In some embodiments, the invention provides a club head with a sole or crown insert that press-fits or snap-fits into place from within the inside of the club head. FIGS. 35-37 show a club head body 142 configured to receive internal insert 145. As shown in FIG. 35, club head body 142 can be separated from face member 141. Face member 141 is mounted to club head body by one or more of cantilever 173 (discussed in more detail with respect of FIGS. 43-49, below).

To attach insert 145 to club head body 142, face member 141 is removed. Insert 145 is pushed into body 142 from the front aperture. Insert 154 deforms slightly (e.g., by plastic/elastic deformation) and then snaps into place within club body 142. As shown in FIG. 35, body 142 has band 143 dimensioned to correspond to groove 147 on insert 145. Once insert 145 is snapped into place, it can be held in place because an outer edge of insert 145 deforms (compresses) to be insert, and then returns to original shape such that the edge overlaps the edge of the corresponding void in body 142. Insert 145 can similarly be removed by squeezing it from a heel side and a toe side such that the outer edge compress, and then pushing it into the inner volume of body 142 and removing it from the aperture at the front of body 142.

FIG. 35 shows a translucent or transparent insert 145 and FIG. 36 illustrates an opaque insert 146 that functions in the same manner. FIG. 37 shows an assembled club head including body 142 and insert 146 or insert 145.

In certain embodiments, the invention provides a club head in which a face component can be separated from a body component through the use of a threaded connection. FIGS. 38 and 39 show face member 151 and body member 155 with corresponding threaded portions. As shown here, face member 151 bears male threaded member 153 and body member 155 bears female threaded recess 155. Body member can be threaded onto face member 153 and screwed tightly into place. In some embodiments, a club head as shown in FIGS. 38 and 39 is provided as a demonstration. For example, any part of the club head is transparent, and the threaded members allow the club head to be separated (e.g., by unscrewing) allowing a golfer to visually inspect an inside detail of the club head, such as layers of construction of a crown, skirt, or sole. In certain embodiments, such a club head is not meant for playing golf, but is provided primarily as a tool for displaying other features in a club head. In some embodiments, such a separable club head is provided as a novelty item, such as a toy for children, a canteen or flask, a tee case, or a gag gift or marketing prop. In certain embodiments, one of male threaded member 153 and female threaded recess 155 corresponds in dimensions to some commonly available threaded item (such as a mason jar or wide mouth drink bottle) allowing a golfer to make amusing assemblies.

In certain embodiments, the invention provides a strap-based assembly system that uses Velcro, snaps, clasps, or adhesives. FIGS. 40-42 illustrate a club head 161 with a crown member 165 having a groove 167 therein. When the crown member 165 is positioned on club head 161, first strap 162 can be fastened to second strap 164, holding the crown member 165 in place. In certain embodiments, the straps fasten by Velcro. A club head of the invention can have one or more straps, individually or in combination, that bind to or surround a portion of a club head for functional or aesthetic purposes. For example, in some embodiments, a club head includes a strap (e.g., nylon, rubber, or leather) that extends in a face-aft direction, as shown in FIG. 40. In certain embodiments, a strap member extends around a club head, entirely or in part, in a heel-toe direction. Further, straps may extend in both directions or at angles relative to those directions. Straps may be decorative. Straps may be used to carry weight members or electronics-related items (e.g., devices such as shot-tracking devices with accelerometers or LCD screens). Straps may be provided as described (e.g., as wrapping elements) in U.S. Pat. No. 7,896,753, the contents of which are hereby incorporated by reference in their entirety for all purposes.

In some aspects, the invention provides club heads that include cantilevered attachments. FIGS. 43-49 show cantilevers.

FIG. 43 shows a face member 171 having a number of cantilever 173 protruding therefrom. Body member 175, shown in FIG. 45, has a number of recess 177 located and dimensioned to correspond to tips 176 of cantilevers 173. When face member 171 is mated to body member 175, cantilever tips 176 snap into place in recesses 177, fastening the club together.

Either of the face member or body member may further include sets of corresponding tab 187 and slot 180 to aid in positioning the body members together.

In some embodiments (not pictured), recesses 177 are holes through a part of the club head, and the cantilevered component can be removed from the component with holes by pressing in on the tips 176. It will be appreciated that this describes a functionality that is related to that described with reference to FIGS. 24 and 25. Depressable engagement pad 92 and receiving hole 93 can be a related embodiment of cantilever 173 and recess 177, and vice versa.

In some embodiments, a body member 175 includes decoupling holes 183. A tool 181 is provided, as shown in FIG. 44, having a prong set 185 dimensioned to be inserted into decoupling holes 183. Prong set 185 pushes cantilever tips 176 out of depressions 177, allowing club head components to be separated from one another.

FIGS. 46-49 show configurations of cantilevered posts and recesses. FIG. 46 shows a cantilever 173 having a squared tip 176 designed to inseparably couple two components of a club head.

FIG. 47 shows an angled tip 176 designed to be slid out from recess 177 allowing components to be decoupled.

FIG. 48 shows another embodiment of decoupling holes 183 arranged so that prong set 185 pushes on a distal tip of cantilever 173.

FIG. 49 shows a spring cantilever 174 having a protruding tab 178 available from an outside of a club head that can be manually squeezed to decouple components of a club head.

In certain aspects and embodiments, the invention provides separable components of multi-component club heads that employ a cam mechanism for releasably joining components. FIGS. 50A-50C show a club head 301 with component 305 having cam mechanism 313. As shown in FIG. 50A, club head 301 has a void opening 311 dimensioned to mate with component 305. One portion of component engages at a perimeter of void opening 311. Here, component 305 is shown having hooks to catch bar 307. Any suitable engagement mechanism can be used. With a portion of component 305 engaged at void opening 322, cam mechanism 313 can be rotated into place to produce a fastened-together club head as shown in FIG. 50B. FIG. 50C is a cross-section of club head 301 showing bar 307 receiving hooks of component 305, and cam mechanism 313 rotated into place.

FIG. 51 is a detail view of the cam mechanism of FIGS. 50A-50C illustrating cam axis 321 through cam mechanism 313. FIG. 52 illustrates radii around a cam axis. In certain embodiments, as shown in FIGS. 50-51, component 305 is dimensioned to engage with club head 301 such that some deformation of component 305 is required to remove it. As shown in FIGS. 50A and 50C, an aft portion of component 305 bends under and forward, while an aft portion of the perimeter of void opening 311 extends upwards and aft-ward. These two portions hook together (i.e., requiring some deformation of component 305 to put it into place on club head 301). When cam 313 is rotated into place, it abuts a surface of component 305 and prevents the deformation of component 305 that would be necessary to remove the component from the club.

As shown in FIG. 50A, cam mechanism 313 may have a tool engagement surface 319 capable of engaging with a tool. A golfer can engage the tool with tool engagement surface 319 to have leverage from the handle of the tool to release cam mechanism 313 from the fastened position.

Turning now to FIGS. 51 and 52, the operation of cam mechanism 313 is illustrated. As shown in FIG. 52, an outer surface of cam mechanism 313 defines a non-constant radius around cam axis 321. When cam mechanism 313 is fastened into place on an assembled golf club, cam axis 321 is spaced away from an adjacent portion of the club head by an engaged radius Rx. Cam mechanism 313 may further be dimensioned such that, when it is fully released (e.g., in the “up” position compared to FIG. 50A), cam axis 321 is spaced away from the adjacent portion of the club head by a minimum radius R_min. Releasing cam mechanism 313 requires pushing it through an orientation in which cam axis 321 is spaced away from the adjacent portion by a maximum radius R_max. The relative dimensions of the radii (e.g., R_min<R_X<R_Max) prevents cam mechanism from releasing unexpectedly. Force must be applied (e.g., through the use of a tool) to deform component 305 enough to allow R_Max to pass the adjacent portion of the club head. Because cam mechanism 313 presents the minimum radius to the adjacent portion when it is in the released position. component 305 has the most space to allow for easy removal from club head 301.

In certain embodiments, the amount of deformation required to remove component 305 from club 301 is close to the limit of perception for most people. A user may intuitively realize that they are deforming component 305 to attach it and remove it, but component 305 may not exhibit substantial deformation. In some embodiments, deformation of component 305 is elastic, plastic, or a combination thereof.

In some embodiments, a cam-based mechanism (e.g., as illustrated in FIG. 51) is used with another fastening mechanism. For example, a cam can be provided with a cantilever 173 (e.g., as illustrated in FIG. 43) such that, when the cam is engaged, cantilever 173 is prevented from exhibiting any deformation such that, for example, aft component 175 is fixed to face component 171 (making reference to FIGS. 43 and 45).

In certain embodiments, a cam is integrally formed with a fastening member. For example, FIGS. 53A-53D show a club head 331 with cam member 339 integrally formed with engagement hooks 338. As shown in FIGS. 53A-53C, club head 331 includes removable crown 333 including cam member 337 and removable sole 335 including cam member 339. Either or both cam member may have a tool engagement surface to be operated through the use of tool 181. FIG. 53D shows a detail view of cam member 337. Cam member 337 rotates about cam axis 349 bringing engagement hook around engagement member 341. As shown in FIGS. 54A and 54B, engagement member 341 is supported by one or more of arm 342 on club head 331. A surface of cam member 339 engages with a surface at a perimeter of removable sole 335 (the relevant portion of the perimeter of removable sole 335 may be thickened, folded inwards, or provided with an engagement block). When cam member 339 is engaged, it cannot freely release because force is required to push the portion of cam member 339 having R_max past the surface of the perimeter of removable sole 335. However, cam member 339 can be rotated by a golfer. In some embodiments, a golfer can manually rotate cam member 339, for example, because an elongated edge member provides a handle or lever. In certain embodiments, a golfer inserts a tool 181 into tool engagement surface 319 and uses the tool to release the component from the golf club.

In certain embodiments, the invention provides a golf club head with a removable component that fastens to a shaft of the golf club. Without being bound by theory, fastening a removable component to a shaft may provide for a very securely assembled club head due to the fact that the shaft provides a carriage function in that it carries the club head and it carries the energy of a golfer's swing. A component secured to the shaft can transmit any stress energy it is subject to through the shaft to the golfer—just as energy of impact is transmitted from a center of percussion at the club head to the golfer. Thus, when a golf ball is hit, the impact energy is transferred from the club head body through the shaft to the golfer and, simultaneously, from the separable component through the shaft and to the golfer. Accordingly, fastening the separable component to the shaft may tend to inhibit relative stresses between the component and the club head body.

FIGS. 55A-55B show a separable component 355 for club head 351 including a mechanism for coupling to a shaft 361 of a golf club. Club head body 351 includes a cutaway, or void, dimensioned to correspond to component 355. Shaft 361 extends through a hosel of club head body 351, and may include a ferrule 359. Component 355 has a fastening mechanism that includes shaft collar 357 dimensioned to pass into club head body 351 and engage a portion of shaft 361.

As shown in FIG. 55B, component 355 includes a slot that extends in a vertical direction when the club is at address. When component 355 is mounted to body 351, shaft collar 357 is disposed beneath an end of shaft 361. A golfer then lifts the mechanism, sliding shaft collar over the end of shaft 361. FIG. 56 shows shaft collar 357. In some embodiments, shaft collar 357 has a cylindrical portion and two tabs that extend from the cylindrical portion. In some embodiments, the two tabs are spaced apart from one another, at least proximal to the cylindrical portion, while shaft collar 357 is not subject to any stress. Sliding shaft collar 357 upwards through the slot in component 355 can push the tabs together if a portion of the slot has an inverted V shape. Thus, sliding collar 357 up over shaft 361 forms a press-fit between collar 357 and the shaft. Once positioned so, tab 363 can be swung into a closed position, pushing post 365 into hole 369 (which can be a press-fit or snap-fit engagement) so that collar 357 remains firmly mounted to shaft 361. In this way, component 355 is securely mounted to club body 351 to provide a playable club.

In some aspects, the invention includes the realization and development of the idea that a multi-component golf club head may be provided with optimized characteristics by coupling a component to a club head body or another component by fastening the component to the shaft or fastening the component into place through the use of a mechanism that also provides other functionality in the club head. A component may be securely fastened to a club head body through integration with the shaft by a variety of suitable mechanisms. FIGS. 57 and 58A-58C illustrate a mechanism for removably coupling a component to a club head body via the shaft. As seen in FIG. 58A, club head body 371 includes a cutaway void in the crown area dimensioned to receive an insert. While illustrated here as a portion of the crown, a cutaway void and a corresponding insert could define any suitable portion of the club head.

Club head 371 includes hosel recess 383 dimensioned to mate with hosel insert 387 on component 375. Component 375 is coupled to club head body 371 by inserting hosel insert 387 into hosel recess 383 to form an assembled club head 390 as shown in FIGS. 58A-58C. As can be seen in FIG. 57, the cutaway void in club head body 371 has a flange around at least a portion of the perimeter of the void.

Further, as illustrated in FIG. 58A, the cutaway void and the component 375 have corresponding wavy edges. The perimeter edge of the cutaway void is wavy in that it defines one or more lobe 377 corresponding to complementary wavy portion of component 375. The wavy portion of component 375 may further include a webbed portion 379 to slip under lobe 377 to help position component 375 correctly and hold it in place. One insight of the invention is that coupling lines in conformations other than straight may provide unexpected benefits in terms of durability, ease of assembly, sound tuning, among other things. More will be said about non-straight coupling seams below.

Assembled club head 390 may be fastened together for playing by any suitable mechanism. In certain embodiments, club head 390 takes advantage of an interchangeable or repositionable shaft that may, for example, also provide other functionality to a golf club (such as multiple loft angles or different shaft lengths). Interchangeable and repositionable shafts are discussed elsewhere herein. In certain embodiments, a shaft with a fixed ferrule is inserted into the hosel of component 375. Club head body 371 has a bore, or hole, for a shaft sleeve screw in the heel region of the sole. A shaft sleeve screw extends through the club head and threads into an end of the shaft. When the shaft sleeve screw is tightened, a compressive force is exerted between the fixed ferrule and the screw head/washer, thereby firmly gripping component 375 to club head body 371. Other mechanisms for coupling the shaft and ferrule to body 371, thereby holding component 375 in place, may include a bayonet mounting mechanism with J-shaped slots (see, e.g., U.S. Pub. 2010/0261543, the contents of which are hereby incorporated by reference in their entirety for all purposes), a threaded portion in hosel recess 383 corresponding to a threaded member on the shaft (see, e.g., U.S. Pat. No. 7,819,754, the contents of which are hereby incorporated by reference in their entirety for all purposes), or other methods known in the art. Mechanisms for golf clubs suitable for operation with the invention, are discussed in U.S. Pub. 2010/0041493; U.S. Pub. 2011/0098128; U.S. Pat. No. 8,057,323, U.S. Pat. No. 1,879,117 and U.S. Pat. No. 3,096,982, incorporated by reference herein in their entirety.

As discussed above, in certain embodiments, a component mates with a club head body or with another component via a non-straight seam line (e.g., not a straight line when viewed along a surface of an assembled club head). FIGS. 58A-58C and FIG. 59 show embodiments including non-straight seams. In some embodiments, coupling seams include wavy lines. Wavy can include, for example, lines that—when projected onto a surface—have at least three inflection points that can be connected by an arc. Wavy can include lines or edges that may generally be described as lobed, scalloped, or wavy.

One insight of the invention is that a golf company may desire to provide a family of similar, but not identical, club heads, each having a separable component. For example, a golf company may provide two drivers having the same model name, wherein one is a few cubic cm larger than the other (e.g., men's and women's models). Each club head can be provided with a separable component that has a functionally similar coupling mechanism and occupies a similar portion of an assembled club head. To avoid golfer confusion, different clubs can be provided with distinct wavy line patterns in the coupling seams. For example, the 455 cubic cm driver may have a wavy assembly seam line with three lobes on the club head body that interlock with two lobes on the separable component, whereas a 425 cubic cm driver may have a “tight wave” assembly seam line with seven lobes on the club head body that interlock with six lobes on the component. Through this mechanism, the separated components will each have a distinct appearance such that a golfer can easily reach for and pick up only the appropriate one when assembling a golf club.

For example, according to this example, a golfer who owns the 425 cubic cm model could enter a pro-shop seeking to purchase a newly-released component with some attractive feature (such as a translucent material in the component that reveals a digital LED screen of an electronic component within the club head). Knowing that their club head included the seven-lobed edge, the golfer—when looking at the components in the display case—can easily focus their attention on only those that fit with their club head.

Moreover, it is an insight of the invention that wavy lines may provide functional and structural advantages. For example, when coupling a component to a club head body (e.g., outdoors in the elements), it may be easier to achieve a proper fitting (i.e., easier to “seat” the part in place) if the wavy edges guide the component into the proper seating.

Further, the stability of the coupling of multi-components may be limited by degrees of freedom of relative motion between the two components. For example, when a cross sectional-profile of a component is curved (see, e.g., component 26 in FIG. 2), coupling the component to the club head body may leave open certain degrees of freedom (e.g., lateral translation in a front-back direction of the component relative to the club head). Providing a wavy coupling seam as shown in FIG. 58A can remove a degree of freedom of relative translation, thereby increasing the security of the coupling of the multiple club head components.

Beyond aiding a golfer in seating a component, and removing degrees of freedom to prevent uncoupling, a wavy seam may provide mating contact lines and surfaces that are oriented desirably relative to a direction of propagation of an impact-associated wave of compression energy. When a club head strikes a ball with force, energy may be transferred through the club head as compression waves that propagate through the materials. Where the waves encounter boundaries between separate components, they may reflect or refract in an undesired fashion if the wave-boundary intersection defines solely and only one certain angle (e.g., less than 45°). For example, given that driver heads may have shapes that have been optimized by generations of engineering design, placing a coupling seam between two components along a substantial portion of the driver head may interfere with impact wave propagation in ways that adversely affect the playability of a club, for example, diminishing its coefficient of restitution, contributing to rapid materials fatigue, or causing very uncomfortable transmissions of vibrations to a golfer's arms. Providing wavy boundaries may tend to preserve the existing, optimized energy propagation characteristics of a club head with multi-component construction.

FIG. 59 shows a club head with multi-component construction in which a boundary seam between component 389 and club head body 381 is wavy. Club head body 381 includes a cutaway void space dimensioned to receive component 389. The void space may bear one or more of support flange 386 spaced around the perimeter. The wavy edge generally defines a series of lobe 377. Component 389 may be provided with webbed portion 379 corresponding to lobe 377 and fitted to extend under an edge of lobe 377, holding component 389 in its proper place in an assembled club head. As shown in FIG. 59, component 389 includes a snap-fit mechanism 388 for removably coupling the component to the club head. FIG. 60 shows a cross-sectional view of snap-fit mechanism 388. Cantilever 60 includes a protrusion that can mate with slot 58. In certain embodiments, a portion of cantilever 600 can be manually manipulated from the outside of an assembled club head to release component 389 from club head body 381.

In some aspects, the invention provides a club head with multi-component construction in which a component includes a malleable material such as rubber. FIG. 61 shows a club head 393 with a malleable component 395 capable of being pulled away from the club head by a peeling, or folding-back action. In some embodiments, as shown in FIG. 61, one edge of a malleable component is permanently fixed the club head (e.g., through cement, or rivets, or similar suitable attachment mechanism). In other embodiments, malleable component 395 is fully removable from club head 393 (e.g., for replacement/interchangeability with another component).

As shown in FIG. 61, malleable component 395 includes a gasket ring 397. Club head 399 bears a corresponding boss portion 399. In some embodiments as shown in FIG. 61, boss portion 399 is rigid (e.g., plastic, metal, or composite) and dimensioned to be pressed into an internal space of gasket ring 397. The pressure between gasket ring 397 and boss portion 399 creates a press-fit that holds component 395 to club head 393 during play. Boss portion 399 can provide functionality to the club head. For example, in certain embodiments, boss portion 399 surrounds a feature such as an opening into the club head, a weight-mounting port, or a mini-USB port. An opening can be provided that allows a golfer to insert a tool into the club head to interact with some other feature within the club head, such as, for example, a tunable mass-distribution mechanism or an assembly tool similar to the one depicted in FIG. 29.

FIGS. 62A and 62B show use of a flap component to fasten a separable component to club head body. As shown in FIG. 62A, club head body 409 includes a cutaway void space dimensioned to receive insert 401. The perimeter of the void space includes one or a number of mounting flanges 411 that can hold insert 401 in place. Further, a portion of insert 401 my include one or number of mounting tabs dimensioned to slip under an edge of the perimeter of the void space. Insert 401 includes a boss portion 399 dimensioned to mate with gasket ring 397 on malleable component 395.

As shown in FIG. 61B, insert 401 can be positioned in the cutaway space of club head 409. Then, malleable component 395 can be used to fasten insert 401 in place, for example, through the use of a press fit between gasket ring 397 and boss portion 399. While insert 401 is here shown as having a wavy perimeter edge to mate with a corresponding wavy edge of the perimeter of the cutaway void in club head 409, this is just one illustrated embodiment. Insert 401 can have any suitable shape including, for example, a rectangle (e.g., to cover a compartment for two AA or AAA batteries), circular (e.g., to cover a screw or weight port), or irregular (e.g., to provide access to some interior mechanism or mass-distribution assembly).

Use of one component to aid in connecting another component allows for benefits in design and manufacturing that may not otherwise be available to club head designers. For example, when an assembled club head includes a separable component joined to the club head body (or another component) along an attachment perimeter, if a portion of the attachment perimeter is covered (for example, by a flexible flap 395), that portion may be manufactured to less precise manufacturing tolerances than if it were uncovered in an assembled, playable club head.

To illustrate, FIG. 61B shows insert component 401 assembled to club head body 409. An aft edge of insert 401, as shown, does not meet and mate with the perimeter of the cutaway void space in club head body 409. However, when flexible flap 395 is pushed into place, no gap between insert 401 and club head body 409 will appear under visual inspection. Accordingly, in certain embodiments, the invention provides a club head having a club head body and a separable insert in which an outer perimeter of the insert and an inner perimeter of a cutaway space in the body define an attachment perimeter. When the insert is coupled to the body, they make contact along a portion of the attachment perimeter and they are optionally spaced away from one another along a portion of the attachment perimeter. Another component of the club head is provided to cover the spaced away portion of the attachment perimeter such that, when the club head is fully assembled, no gaps are visible from the outside of the club head. This allows club head body 409 to be designed and manufactured with a cutaway provided to receive an insert. Then, insert 401 can be designed or manufactured with less stringent attention given to the fit along a portion of the insert, which may allow manufacturing to be faster or less expensive.

In some aspects, the invention provides a component for a club head that forms an assembled, playable club head through the use of magnets. For example, FIG. 63 shows a club head body 501 having a cutaway portion with a protruding flange defining slot 507. A separable sole member 505 has protruding tabs 509 dimensioned to slide into slot 507 to form an assembled club head. Each of club head body 501 and sole member 505 have one or more of boss 513, shown here on an inside surface, holding at least one magnet 523. Any magnet may be used in the invention. In some embodiments, a high-strength magnet such as a rare earth magnet is used (e.g., magnets including neodymium or samarium-cobalt). Magnet 523 can be press-fit into boss 519, held in place by adhesives, threaded in, or held in place by any other suitable method (including, for example, being embedded in plies of pre-peg using, for example, manufacturing methods as discussed in U.S. Pat. No. 6,695,608 the contents of which are hereby incorporated by reference in their entirety for all purposes). Further, magnets may be employed to fix a mass element in place, such as a mass ring as disclosed in U.S. Pub. 2011/0081986, the contents of which are incorporated by reference herein in their entirety for all purposes.

FIG. 64 is a top-down view of boss member 513 with magnet 523 therein. As can be seen from FIG. 64, boss 513 can be positioned to expose a surface of a magnet for interaction with another magnetic material.

FIG. 65 shows another embodiment of the invention using magnets to fasten a component to a club head. Here, insert panel 605 is hooked into club head body 601 via a flange on insert panel 605 received by slot 607. Distal to the flange is a mating surface presented by magnet-including bosses on insert 605 and club head body 601. Looking, for example, at club head body 601, a boss portion 609 extends upwards and includes magnet 613 mounted therein (for example, by one of the methods mentioned above).

Magnetized coupling points can be positioned at any suitable location on a club head. In certain embodiments, separable components are designed to be held in place through the use of magnets that, when on an assembled club head, are located so as to optimize mass distribution (e.g., to increase MOI around a center of percussion on a strike face or to lower a center of gravity).

FIGS. 66-68 illustrate another embodiment using magnets to couple an insert to a club head body. Here, insert 705 is coupled to club head body 701 through one or more of protruding post 706 dimensioned to be received by corresponding slot 708. An aft end of inert 705 includes one or more of magnet 709 (not visible in FIG. 66) exposed on an underside thereof. Club head body 701 further includes one or more of magnet 707. FIG. 68 is a face-aft cross sectional view through magnetic coupling mechanism of insert 705 and club head body 701. Magnet 709 in insert 705 matches up to magnet 707 in club head body 701, thereby fastening the club together for playing golf.

The disclosure herein includes description and discussion of methods and mechanism for assembling components such as inserts, sole plates, crown plates, and components of club heads, and bodies, to one another. The invention includes the insight that one or more of any of any mechanism of the invention, any component of the invention, or any feature of the invention can be combined in any number and in any combination. For example, any given flange arrangement and any given fastening mechanism may be combined—even if not shown together in a figure of the present disclosure—to provide a multi-component club head or club head with separable component or insert. Thus a club head of the present invention may include, for example, barbed posts designed to be broken off to remove a component as well as magnets for fastening components together.

It is an insight of the invention that a number of aspects of a club head can be uniquely selected with a variety of options and that this is well suited to customizing club heads to a customer's desires. It is a related insight that computer device technology provides a valuable tool for managing the complexity of manufacturing where customized orders are included. Accordingly, the invention provides systems and methods for providing a customized club head.

Providing a customized head can include offering options for one or more features that are available with a club head and receiving a selection from a consumer of an option. FIG. 69 depicts a display that can be used to receive a consumer's selection of one or more options for a club head. As shown in FIG. 69, a consumer could be given a display (e.g., in a web browser as presented via a graphical user interface (GUI)) that includes elements such as pull-down menus for choosing options. Any method of offering options and receiving selections is included, such as, for example, point-and-click selection, keyboard entry, radio buttons, and confirmation of suggested options. A selection of an option can include selecting a given option from a set of possibilities and it can also include selecting whether or not to include a certain feature at all. For example, a consumer can be offered whether or not they would like a removable crown panel on their club head and, if they choose so, they can then be offered a list. Options can be offered and selections received for any aspect of a club head including all of those discussed herein. As indicated in FIG. 69, a consumer could choose a material for a crown panel and suitable choices could include, for example, clear plastic, translucent plastic, composite, carbon fiber, titanium, aluminum, alloy.

A customer could be offered choices of bodies and body materials. Choices of certain bodies may govern the availability of certain other choices. For example, some bodies may have a forward member for supporting a strike face and a body skirt member upon which a crown panel and sole plate are to be installed. Where a customer chooses such a body, they may then be offered a choice of sole plate (e.g., with choice of style, material, color, etc.).

Other features a customer could choose options for include overall finish of surface (e.g., anodized, painted, decal set), strike face, removable/interchangeable weight members, reconfigurable shaft, setting indicator window, customer-uploaded photo printed on surface (e.g., as uploaded digitally), number of club heads (e.g., customer orders entire set or matching clubs/sets for whole families), etc.

FIG. 69 generally shows an exemplary display as could be shown on a screen, for example, of a computer or smartphone, discussed in more detail below. In certain embodiments, FIG. 69 represents a display rendered in a web browser (e.g., a web page being displayed by Internet Explorer or Google Chrome).

As shown in FIG. 69, receiving customer options can be done via a series of related screens. For example, a customer can choose materials for parts in a first screen, choose optional accessories in another screen, and save their choices and pick colors in another screen. However, in other embodiments, all choices are made on a single screen or a different combination of screens. In certain embodiments, choices are suggested based on inferences made according to computer program rules about a customer's likely preference. For example, if a customer orders a shaft in a given color (e.g., orange), a club head can be shown and suggested with a given matching or complementary color (e.g., orange main material with blue contrast finish details, or all green panels).

Given the variety of options a customer may choose and the variety of numbers a customer may order, the invention provides methods of receiving and preparing customized orders. FIG. 70 gives a high-level block diagram of steps of a method of providing a customized club head according to certain embodiments of the invention. A method of providing a customized club head according to certain embodiments of the invention can include receiving a customer's choice of a product (e.g., AMP-product line driver club head) and showing the customer a product example (e.g., FIG. 69). A customer's selections of an option are received and saved in a memory. If the selection reflects a change from what was previously shown, the displayed product view can be updated to show what the customer has chosen. This can be repeated for as many features as are customizable or as many features as the customer chooses to select options for.

If the customer ends up not placing an order, they can be returned to browsing (e.g., shown a web page home screen or another product screen). Their choices can be saved and displayed to them at a later web page visit.

If the customer places an order, methods of the invention include capturing information from the customer about how they will pay for the product and how they will receive it. For example, a customer can provide a credit card number over a computer network (e.g., by typing into a payment web page), and then choose shipping by expedited mail and provide their home address. Or, alternatively, a customer can indicate that they wish to use a corporate account (e.g., they are purchasing a dozen club heads that are printed with a corporate logo which they have uploaded an image file such as a TIFF) and they can specify delivery to some site. A customer can also choose in-store pickup. In certain embodiments, a method of providing a customized club head is operable in conjunction with a special event, and methods include capturing delivery information about providing the club heads at the special event. For example, if Acme Golf Co is sponsoring and staffing a booth at Corporate Inc.'s charity fund-raiser, Acme Golf Co can collect information from a person at Corporate Inc. about a customized golf club (e.g., as a promotional item or prize) via methods of the invention, and Acme Golf Co can bring the golf club to the booth at the charity fund-raiser.

After delivery information is captured, it is determined whether the ordered item is already in stock, as-ordered. If it is, the ordered item is shipped or prepared for delivery according to the customer's delivery information. If the ordered item is not in stock, the order is batched.

Methods of the invention include organizing sets of orders for efficient production. A computer program, executed by a processor, can make reference to information about production facilities to organize a plurality of different orders and to coordinate production instructions so that production facilities include minimal down-time while components or parts are “switched out”. For example, if regular production is scheduled for ten gross of aluminum club head bodies and ten gross of titanium club head bodies, and customized orders have been placed for one composite body, one aluminum body, one titanium body, and one alloy body, then order batching can include listing the order, for example, in the following order: 1441 aluminum; 1441 titanium; lcomposite; 1 alloy.

Order batching further includes scheduling production of individual batches, where a batch is a sub-set of all orders identified by a computer executing program instructions according to production criteria. Batches may be scheduled according to information about production times, steps, complexity, or interrelationships involved. For example, if a repositionable shaft connection is required to be added to a club head at an assembly workstation where a main body of a club head is painted, while a sole plate is added to a club head at a dedicated separate workstation and can only be added after a main body is painted, then a batch can be prepared that is all club heads with repositionable shaft connections batched with all club heads to be painted, while a separate batch is prepared that includes all club heads with a sole plate. Then, the second batch can be routed to the main assembly work station first, for example, to leave additional time for adding the repositionable shaft connection to that batch while the other batch is at the main assembly workstation so that the entire set of batches is completed at the same time.

After order batching, order information (e.g., info regarding batches, production schedules, and individual orders of club heads) is transmitted to a production system or facility, and the ordered club heads are produced.

After production, the club heads are sent. If a customer has ordered a club to be shipped to their home, the club is sent to the customer. If a customer has requested in-store pickup, the club is sent to the store. If a customer has requested another delivery option, it is so initiated.

The invention provides systems suitable for implementing methods of providing a customized golf club including the foregoing methods. FIG. 71 shows components in an exemplary system for providing a customized golf club. As shown in FIG. 71, system 200 generally includes one or more computer, communicably coupled via network 215. Systems and methods of the invention may generally be implemented through the use of one or more computer such as any combination of a provider computer 281, a production computer 261, and a consumer computer 201 along with, for example, a sales server 241 and a production server 221. A computer generally includes a processor (e.g., 209, 289, 269, 249, 229) operably coupled to a memory (e.g., 207, 287, 267, 247, 227) and configured to send or receive information via input-output device (e.g., 205, 285, 265, 245, 225).

One of skill in the art will recognize that a processor may be provided by one or more processors including, for example, one or more of a single core or multi-core processor (e.g., AMD Phenom II X2, Intel Core Duo, AMD Phenom II X4, Intel Core i5, Intel Core i& Extreme Edition 980×, or Intel Xeon E7-2820). In certain embodiments, any of consumer computer 201, provider computer 281, production computer 261 may be a notebook or desktop computer sold by Apple (Cupertino, Calif.) or a desktop, laptop, or similar PC-compatible computer such as a Dell Latitude E6520 PC laptop available from Dell Inc. (Round Rock, Tex.). Such a computer will typically include a suitable operating system such as, for example, Windows 7, Windows 8, Windows XP, all from Microsoft (Redmond, Wash.), OS X from Apple (Cupertino, Calif.), or Ubuntu Linux from Canonical Group Limited (London, UK). In some embodiments, any of consumer computer 201, provider computer 281, production computer 261 may be a tablet or smart-phone form factor device and processor 281 can be provided by, for example, an ARM-based system-on-a-chip (SoC) processor such as the 1.2 GHz dual-core Exynos SoC processor from Samsung Electronics, (Samsung Town, Seoul, South Korea).

In some embodiments, either of sales server 241 or production server 221 can be a Hitachi Compute Blade 500 computer device sold by Hitachi Data Systems (Santa Clara, Calif.). Either of processor 249 or processor 229 can be, for example, a E5-2600 processor sold under the trademark Xeon by Intel Corporation (Santa Clara, Calif.).

Input-output devices generally includes one or a combination of monitor, keyboard, mouse, data jack (e.g., Ethernet port, modem jack, HDMI port, mini-HDMI port, USB port), Wi-Fi card, touchscreen (e.g., CRT, LCD, LED, AMOLED, Super AMOLED), pointing device, trackpad, microphone, speaker, light (e.g., LED), or light/image projection device.

In certain embodiments, a consumer's selection of options is received via the consumer's use of consumer computer 201 and the selection is received at sales server 241 and stored in memory 247. Sales server 241 uses a network card for input/output 245 to received data. Sales server 241 maintains order database 243 which may include accounts 244 where consumer information is stored (e.g., for payment and delivery information).

After orders are received and ready for production, digital files can be transferred via input/output 245 from sales server 241 to production server 221 via input/output 225, which may also be a network card or other data transfer mechanism. Order information (e.g., orders 239) is stored in production database 235 in memory 227. Processor 229 executes computer program instructions stored in memory 229 to perform order batching and to initiate production.

A production facility may be equipped with a production computer 261 which either automatically coordinates the operation of machines or provides information to production employees, e.g., via input/output 265, which could include, for example, a monitor or laser printer.

Many of the steps and functions described herein can be planned or coordinated by a provider personnel using provider computer 281. For example, engineers or sales personnel can prepare and upload information (e.g., digital files such as in a comma-separated values (CSV) format) that, for example, lists options for features for consumer selection. That is, in certain embodiments, provider personnel use provider computer 281 to “set up” what options are available, for example, within a display such as the one shown in FIG. 69. Such uploaded information may be saved in memory 247 on sales server 241 and can be used, for example, by processor 249 to cause a display to be rendered such as that shown in FIG. 27 on input/output 205 on consumer computer 201. Input/output 205 can include a monitor displaying a view of a web browser. A customer's selection of options can be stored in one of accounts 244 in order database 243 by writing a file in memory 247.

A memory generally refers to one or more storage devices for storing data or carrying information, e.g., semiconductor, magnetic, magneto-optical disks, or optical disks. Information carriers for a memory suitable for embodying computer program instructions and data include any suitable form of memory that is tangible, non-transitory, non-volatile, or a combination thereof. In certain embodiments, a device of the invention includes a tangible, non-transitory computer readable medium for memory. Exemplary devices for use as memory include semiconductor memory devices, (e.g., EPROM, EEPROM, solid state drive (SSD), and flash memory devices e.g., SD, micro SD, SDXC, SDIO, SDHC cards); magnetic disks, (e.g., internal hard disks or removable disks); magneto-optical disks; and optical disks (e.g., CD and DVD disks). The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

The subject matter described herein can be implemented in a computing system that includes a back-end component (e.g., sales server 241 or production server 221), a middleware component (e.g., an application server or sales sever 241), or a front-end component (e.g., consumer computer 201 having a graphical user interface or a web browser through which a user can interact with an implementation of the subject matter described herein), or any combination of such back-end, middleware, and front-end components. The components of the system can be interconnected through network 215 by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include cell network (e.g., 3G or 4G), a local area network (LAN), and a wide area network (WAN), e.g., the Internet.

The subject matter described herein can be implemented as one or more computer program products, such as one or more computer programs tangibly embodied in an information carrier (e.g., in a non-transitory computer-readable medium) for execution by, or to control the operation of, data processing apparatus (e.g., a programmable processor, a computer, or multiple computers). A computer program (also known as a program, software, software application, app, macro, or code) can be written in any form of programming language, including compiled or interpreted languages (e.g., C, C++, Perl), and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. Systems and methods of the invention can include instructions written in any suitable programming language known in the art, including, without limitation, C, C++, Perl, Java, ActiveX, HTML5, Python, Ruby on Rails, Visual Basic, or JavaScript. In certain embodiments, systems and methods of the invention are implemented through the use of a mobile app. As used herein, mobile app generally refers to a standalone program capable of being installed or run on a smartphone platform such as Android, iOS, Blackberry OS, Windows 8, Windows Mobile, etc.

Functionality of the invention can be implemented by a mobile app or a software application or computer program in other formats included scripts, shell scripts, and functional modules created in development environments.

A computer program does not necessarily correspond to a file. A program can be stored in a portion of a file that holds other programs or data, in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.

A file can be a digital file, for example, stored on a hard drive, SSD, CD, or other tangible, non-transitory medium. A file can be sent from one device to another over network 215 (e.g., as packets being sent between a server and a client, for example, through a Network Interface Card, modem, wireless card, or similar).

Writing a file according to the invention involves transforming a tangible, non-transitory computer-readable medium, for example, by adding, removing, or rearranging particles (e.g., with a net charge or dipole moment into patterns of magnetization by read/write heads), the patterns then representing new collocations of information about objective physical phenomena desired by, and useful to, the user (e.g., a physical arrangement of particles that indicates that a specific, new club head is to be constructed from a certain set of multiple components and sent to a customer). In some embodiments, writing involves a physical transformation of material in tangible, non-transitory computer readable media (e.g., with certain optical properties so that optical read/write devices can then read the new and useful collocation of information, e.g., burning a CD-ROM). In some embodiments, writing a file includes transforming a physical flash memory apparatus such as NAND flash memory device and storing information by transforming physical elements in an array of memory cells made from floating-gate transistors. Methods of writing a file can be invoked manually or automatically by a program or by a save command from software or a write command from a programming language.

As used herein, the word “or” means “and or or”, sometimes seen or referred to as “and/or”, unless indicated otherwise. Any documents referenced in the disclosure are hereby incorporated herein by reference in their entirety for all purposes.

Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments can be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.

Any patent or publication mentioned herein is hereby incorporated by reference in entirety for all purposes.

Claims

1. A golf club head, comprising:

a body member comprising at least one opening for receiving a crown insert, the body member comprising at least one body attachment feature for attaching the body member to the crown insert; and

a crown insert attached to the body member, a majority of the crown insert comprised of plastic, the crown insert comprising at least one crown attachment feature for attaching the crown insert to the body member, the crown insert comprising at least one divider element separating the crown insert into a plurality of plastic portions.

2. The golf club head of claim 1, wherein the plastic portions are transparent.

3. The golf club head of claim 1, wherein the divider elements are flexible, non-plastic, and divide the crown insert into four plastic sections.

4. The golf club head of claim 1, further comprising a releasable weight component releasably attached to the body member, the releasable weight component having at least one specialized tool cavity, the releasable weight component configured to adjust the weight and center of gravity of the club head.

5. A golf club head, comprising:

a body comprising an opening for receiving an insert;

an attachment feature disposed at the opening and presenting a surface comprising a plurality of holes; and

an insert panel comprising a plurality of protrusions dimensioned to be received by the plurality of holes.

6. The golf club head of claim 5, wherein the body comprises at least five holes on the surface, and the insert comprises at least five post-like structures.

7. The golf club head of claim 5, wherein surface comprising a plurality of holes is located on a gasket member, and the gasket member is attached adhesively to the body.

8. The golf club head of claim 5 wherein the insert is a crown insert comprising a majority of the crown, and is comprised at least partially of plastic.

9. A golf club head, comprising:

a body member comprising at least one opening for receiving a sole insert, the body member comprising a first attachment flange disposed at the opening for attachment to the sole insert; and

a sole insert comprising a second attachment flange and attached to the body via the first attachment flange,

wherein the sole insert is configured to be attached to the body member by a snap-fit assembly, without the use of adhesives or welding.

10. The golf club head of claim 9, wherein first attachment flange extends inwardly from the body member towards an open cavity in the club head.

11. The golf club head of claim 9, wherein the first and second attachment flanges are angled.

12. The golf club head of claim 9, wherein the snap-fit assembly comprises a plurality of cantilevers with protruding tips and a recess corresponding to each tip.

13. The golf club head of claim 9, wherein the snap-fit assembly comprises a collar adapted to be swaged onto a post for attachment and unscrewed with a wrench for removal.

13. The golf club head of claim 9, further comprising at least one weight releasably attached to the body member, the weight having at least one specialized tool cavity, the weight screw configured to adjust the weight and center of gravity of the club head.

14. The golf club head of claim 9, wherein the sole insert is selected from a group of different inserts, so as to customize the club head.

15. A golf club head comprising:

a body member having a striking face, a heel-side skirt portion, a toe-side skirt portion, and a hosel;

a shaft-mounting structure within the body member for coupling a shaft through the hosel;

a shaft bolt configured to fasten an end of the shaft within the body; and

a sole insert fastened in place at least in part by the shaft bolt.

16. The club head of claim 15, wherein removing the shaft bolt with a tool allows the sole insert to be manually separated from the club head with no other tools.

17. A golf club head comprising:

a body member having strike face area, a hosel, and an opening having a perimeter;

a weight member releasably attached to the body member; and

an insert panel releasably held in place over the opening at least in part by the weight member.

18. The club head of claim 17, further comprising a flange disposed at the perimeter of the opening and further wherein the insert panel comprises:

a hole through which a portion of the weight member extends when attached to the body member;

an attachment feature spaced away from the hole for coupling to the body member.

19. A set of inserts for customizing a golf club, the set comprising:

at least two insert panels each having an exterior surface, an interior surface, and a perimeter portion; and

an attachment feature at the perimeter portion of each insert panel, wherein the two insert panels have substantially the same morphology at the perimeter portion and are adapted to be interchangeably coupled to a club head, and further wherein the two insert panels are not identical.

20. The set of claim 19, wherein at least one of the insert panels is translucent.

21. The set of claim 19, wherein the attachment feature comprises one selected from the list consisting of: barbed posts; adhesive; protruding boss for coupling via a shaft screw; recess for receiving a protruding tip of a cantilever; and swage-on/twist-off fastening mechanism.

22. The set of claim 19, wherein the two insert panels further comprise unlike morphologies at their exterior surfaces.

23. The set of claim 19, further comprising a third insert panel.

24. A method of providing a customized golf club head, the method comprising:

receiving a consumer's selection of an option and storing the selection in a tangible, non-transitory memory;

creating, through the use of a computer processor coupled to the memory, a digital file including information about a club head including the selected option;

transferring the information to a production site; and

producing a customized club head including the selected option.

25. The method of claim 24, wherein the consumer's selected option comprises a choice of insert to be provided with the club head.

26. A system for providing a customized golf club, the system comprising:

a computer including a tangible, non-transitory memory coupled to a processor, the computer configured to execute instructions causing it to:

receive a consumer's selection of an option and store the selection in a tangible, non-transitory memory;

create, through the use of a computer processor coupled to the memory, a digital file including information about a club head including the selected option;

transfer the information to a production site; and

write a file comprising billing and shipping data for use in a sale transaction.

27. A golf club head, comprising:

a body member comprising an opening dimensioned to receive an insert;

a bore through the hosel and a sole portion of the club head to receive a removable shaft; and

an insert dimensioned to fit into the opening to form an assembled club head, wherein the insert is fastened into place by fastening a shaft to the assembled club head.

28. A golf club head, comprising:

a body member comprising an opening dimensioned to receive an insert;

an insert having an outer perimeter portion configured to mate with an inner perimeter portion of the opening to define an attachment perimeter, wherein at least a portion of the attachment perimeter defines a line that, when projected onto a plane, comprises three inflexion points that can be connected with an arc having no inflexion points in the plane.

29. A golf club head comprising:

a body member comprising a feature for mating with a malleable component; and

a malleable component adapted to mate with the feature to provide an assembled club head.

39. The club head of claim 29, wherein the malleable component comprises rubber and the feature is a raised, rigid boss.

40. A golf club head, comprising:

a body member comprising an opening dimensioned to receive an insert;

an insert adapted to be coupled to the opening to provide an assembled club head; and

a fastening mechanism including a cam that fastens the insert to the assembled club head.

41. The club head of claim 40, wherein the cam is part of a lever member having a tool engagement surface.

42. The club head of claim 40, wherein the fastening mechanism further includes at least one engagement hook.

43. A golf club head, comprising:

a body member comprising an opening dimensioned to receive an insert;

an insert adapted to be coupled to the opening to form an assembled club head for a golf club and further wherein the insert includes a mechanism for fastening the insert to a shaft of the golf club.