GOLF CLUB HEAD WITH PNEUMATIC INSERT

Description

CROSS REFERENCE PRIORITIES

This is a continuation-in-part of U.S. patent application Ser. No. 18/629,872, filed on Apr. 8, 2024, which claims the benefits of U.S. Provisional Application No. 63/494,763, filed on Apr. 6, 2023; and U.S. Provisional Application No. 63/590,338, filed on Oct. 13, 2023. This further claims the benefit of U.S. Provisional Application No. 63/694,660, filed Sep. 13, 2024; U.S. Provisional Application No. 63/730,532, filed Dec. 11, 2024; and U.S. Provisional Application No. 63/777,569, filed Mar. 25, 2025, the contents of which are fully incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates generally to golf clubs and, more particularly, to iron-type golf club heads.

BACKGROUND

Golf club head design contemplates several performance characteristics, such as vibrational response at impact. The vibrational response corresponds to the sound and feel of the golf club. Excessive, dominant vibrations experienced at impact produce a loud, acoustically displeasing sound and a harsh, unnerving feeling in the hands of the golfer. Many prior art golf club heads, particularly iron-type golf club heads, attempt to damp such undesirable vibrations by filling the club head cavity with an insert or filler material.

Although such inserts or filler materials can improve the club head vibrational response, they often negatively affect ball flight performance by creating undesirable club head weight distributions. Specifically, prior art inserts and filler materials are often solid materials, such as solid polymeric inserts, solid foam inserts, metallic inserts, or badges. These inserts and filler materials reduce club head discretionary mass available to improve club head mass properties, such as moment of inertia (MOI) and/or center of gravity (CG) position, via perimeter weighting. In many cases, securing a prior art insert to the club head body requires robust retaining features and/or components, such as casings or mechanical fasteners. Such components further reduce club head discretionary mass. Accordingly, prior art inserts lack a lightweight solution to dampen club head vibrations that allow the designer to create desirable club head weight distribution. Such a solution creates a golf club head exhibiting a pleasing sound, a soft feel at impact, and increased discretionary mass to improve ball flight performance.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate further description of the embodiments, the following drawings are provided in which:

FIG. 1 illustrates a front perspective view of a golf club head according to the present invention.

FIG. 2 illustrates a rear perspective view of the golf club head of FIG. 1.

FIG. 3 illustrates a front view of the golf club head of FIG. 1.

FIG. 4 illustrates a toe-side view of the golf club head of FIG. 1.

FIG. 5 illustrates a toe-side, cross-sectional view of the golf club head of FIG. 1, devoid of a pneumatic insert.

FIG. 6 illustrates a front, cross-sectional view of the golf club head of FIG. 1, comprising a pneumatic insert.

FIG. 7 illustrates a toe-side cross-sectional view of the pneumatic insert illustrated in FIG. 6, wherein the cross-section is taken along line A-A of FIG. 6.

FIG. 8A illustrates a front, cross-sectional view of a pneumatic insert comprising multiple sub-chambers.

FIG. 8B illustrates a front, cross-sectional view of a second embodiment of a pneumatic insert comprising multiple sub-chambers.

FIG. 8C illustrates a front, cross-sectional view of a third embodiment of a pneumatic insert comprising multiple sub-chambers.

FIG. 8D illustrates a front, cross-sectional view of a fourth embodiment of a pneumatic insert comprising multiple sub-chambers.

FIG. 9 illustrates a rear view of a golf club head according to one embodiment of the present invention, with the pneumatic insert removed.

FIG. 10 illustrates a toe-side cross-sectional view of the golf club head of FIG. 9.

FIG. 11 illustrates a rear view of the golf club head of FIG. 9, including a pneumatic insert.

FIG. 12 illustrates a toe-side cross-sectional view of the golf club head of FIG. 9, including a pneumatic insert.

FIG. 13 illustrates a rear perspective view of the golf club head of FIG. 9.

FIG. 14 illustrates a rear view of a golf club head according to another embodiment of the present invention.

FIG. 15 illustrates a rear perspective view of the golf club head of FIG. 14, with a badge removed.

FIG. 16 illustrates a cross-sectional view of the golf club head of FIG. 14, with the pneumatic insert removed.

FIG. 17 illustrates a toe-side, cross-sectional view of the golf club head of FIG. 14.

FIG. 18 illustrates a front, cross-sectional view of the golf club head of FIG. 14.

FIG. 19 illustrates a rear view of a golf club head according to another embodiment of the present invention.

FIG. 20 illustrates a rear view of the golf club head of FIG. 19, with the badge removed.

FIG. 21 illustrates a toe-side, cross-sectional view of the golf club head of FIG. 20.

FIG. 22 illustrates a front, cross-sectional view of the golf club head of FIG. 19.

FIG. 23 illustrates a rear perspective view of a golf club head according to another embodiment of the present invention.

FIG. 24 illustrates a toe-side, cross-sectional view of the golf club head of FIG. 23.

FIG. 25 illustrates a front, cross-sectional view of the golf club head of FIG. 23.

FIG. 26 illustrates an installation assembly for installing a pneumatic insert according to the present invention.

FIG. 27 illustrates a front, cross-sectional view of a golf club head comprising a pneumatic insert and one or more top rail bumpers.

FIG. 28 illustrates a toe-side, cross-sectional view of the golf club head of FIG. 27.

FIG. 29 illustrates an enlarged detail view of the golf club head of FIG. 27, highlighting a top rail bumper.

FIG. 30 illustrates a front, cross-sectional view of a golf club head comprising a pneumatic insert and one or more sole bumpers.

FIG. 31 illustrates a rear perspective view of the golf club head of FIG. 30, with the pneumatic insert and the badge removed.

FIG. 32 illustrates a rear view of a golf club head comprising a pneumatic insert and one or more back face bumpers.

FIG. 33 illustrates a rear view of the golf club head of FIG. 32, with the pneumatic insert removed.

FIG. 34 illustrates a toe-side, cross-sectional view of a golf club head comprising one or more full-cavity bumpers.

FIG. 35 illustrates a front view of a badge comprising one or more badge bumpers.

FIG. 36 illustrates an exploded view of a golf club head comprising a pneumatic insert and a badge comprising one or more badge bumpers.

FIG. 37A illustrates a rear view of a golf club head comprising multiple pneumatic inserts.

FIG. 37B illustrates a front cross-sectional view of the golf club head of FIG. 37A.

FIG. 38A illustrates a rear view of a second embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 38B illustrates a front cross-sectional view of the golf club head of FIG. 38A.

FIG. 39A illustrates a rear view of a third embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 39B illustrates a front cross-sectional view of the golf club head of FIG. 39A

FIG. 40A illustrates a rear view of a fourth embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 40B illustrates a front cross-sectional view of the golf club head of FIG. 40A.

FIG. 41A illustrates a rear view of a fifth embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 41B illustrates a front cross-sectional view of the golf club head of FIG. 41A.

FIG. 42A illustrates a rear view of a sixth embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 42B illustrates a front cross-sectional view of the golf club head of FIG. 42A.

FIG. 43A illustrates a rear view of a sixth embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 43B illustrates a front cross-sectional view of the golf club head of FIG. 43A.

FIG. 44A illustrates a rear view of a seventh embodiment of a golf club head comprising multiple pneumatic inserts.

FIG. 44B illustrates a front cross-sectional view of the golf club head of FIG. 44A.

FIG. 45 illustrates a front perspective cross-sectional view of a golf club head comprising a localized pneumatic insert.

FIG. 46 illustrates a front perspective cross-sectional view of another embodiment of a golf club head comprising a localized pneumatic insert.

FIG. 47 illustrates a front perspective cross-sectional view of another embodiment of a golf club head comprising a localized pneumatic insert.

FIG. 48 illustrates a front perspective cross-sectional view of another embodiment of a golf club head comprising a localized pneumatic insert.

FIG. 49 illustrates a front perspective cross-sectional view of a golf club head comprising a corrugated pneumatic insert.

FIG. 50 illustrates a toe-side cross-sectional view of the golf club head of FIG. 49.

FIG. 51 illustrates a front perspective cross-sectional view of a golf club head including a pneumatic insert comprising a crease.

FIG. 52 illustrates a front perspective cross-sectional view of a second embodiment of a golf club head including a pneumatic insert comprising a crease.

FIG. 53 illustrates a front perspective cross-sectional view of a golf club head comprising

a localized pneumatic insert with internal reinforcing features.

FIG. 54 illustrates a toe-side cross-sectional view of the golf club head of FIG. 53.

FIG. 55 illustrates a front perspective cross-sectional view of a second embodiment of a golf club head comprising a localized pneumatic insert with internal reinforcing features.

FIG. 56 illustrates a toe-side cross-sectional view of the golf club head of FIG. 55.

FIG. 57 illustrates a front perspective cross-sectional view of a golf club head comprising a pneumatic insert with a slot.

FIG. 58 illustrates a toe-side cross-sectional view of the golf club head of FIG. 57.

FIG. 59A illustrates a front perspective view of a pneumatic insert comprising one or more solid portions.

FIG. 59B illustrates a toe-side view of the pneumatic insert of FIG. 59A.

FIG. 60A illustrates a front perspective view of a second embodiment of a pneumatic insert comprising one or more solid portions.

FIG. 60B illustrates a toe-side view of the pneumatic insert of FIG. 60A.

FIG. 61A illustrates a front perspective view of a third embodiment of a pneumatic insert comprising one or more solid portions.

FIG. 61B illustrates a toe-side view of the pneumatic insert of FIG. 61A.

FIG. 62A illustrates a front perspective view of a third embodiment of a pneumatic insert comprising one or more solid portions.

FIG. 62B illustrates a toe-side view of the pneumatic insert of FIG. 62A.

FIG. 63A illustrates a front perspective view of a pneumatic insert comprising one or more insert ribs.

FIG. 63B illustrates a front perspective view of a second embodiment of a pneumatic insert comprising one or more insert ribs.

FIG. 63C illustrates a front perspective view of a third embodiment of a pneumatic insert comprising one or more insert ribs.

FIG. 63D illustrates a front perspective view of a fourth embodiment of a pneumatic insert comprising one or more insert ribs.

FIG. 64 illustrates a front perspective view of a pneumatic insert comprising one or more internal weight members.

FIG. 65 illustrates a front, cross-sectional view of a golf club head according to another embodiment of the present invention.

FIG. 66 illustrates a toe-side, cross-sectional view of the golf club head of FIG. 65.

FIG. 67 illustrates a front perspective cross-sectional view of a golf club head including a pneumatic insert comprising an aperture with a web.

FIG. 68 illustrates a front perspective cross-sectional view of a golf club head including a pneumatic insert comprising a pinched column.

FIG. 69 illustrates a front perspective cross-sectional view of a golf club head including a pneumatic insert comprising a keyhole-shaped aperture.

FIG. 70A illustrates a front-side view of a pneumatic insert comprising a keyhole-shaped aperture in an operative state.

FIG. 70B illustrates a front-side view of the pneumatic insert of FIG. 70A in a compressed state.

FIG. 71 illustrates a front perspective view of pneumatic insert comprising a keyhole-shaped aperture with a web.

FIG. 72 illustrates a front perspective cross-sectional view of a golf club head comprising another embodiment of a pneumatic insert according to the present invention.

FIG. 73A illustrates a top cross-sectional view of the pneumatic insert of FIG. 72 in a compressed state.

FIG. 73B illustrates a top cross-sectional view of the pneumatic insert of FIG. 73A in an operative state.

FIG. 74 illustrates a front perspective cross-sectional view of a golf club head comprising another embodiment of a pneumatic insert according to the present invention.

FIG. 75 illustrates a front cross-sectional view of the pneumatic insert of FIG. 74.

DEFINITIONS

For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denote the same elements.

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

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

The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements or signals, electrically, mechanically and/or otherwise.

Described herein are various embodiments of a club head comprising a pneumatic insert to improve sound and feel while increasing discretionary mass. FIGS. 1-10 schematically illustrate various embodiments of an iron-type golf club head 100 in various views. For ease of discussion, the features shown on the golf club head 100 are applicable to various embodiments of the club head according to the present invention. Any one or more of the features described in the various embodiments below can be used in combination with one another. Further, while different embodiments may comprise different numbering schemes (i.e., 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., golf club head 100 can comprise a top rail 110 and a sole 112, whereas club head 200 can comprise a top rail 210 and a sole 212).

As illustrated by FIGS. 1 and 2, the club head 100 comprises a club head body 101. The club head body 101 can comprise a front end 108 defining a strike face 102, a top rail 110, a sole 112 opposite the top rail 110, a heel 104, and a toe 106 opposite the heel 104. The club head 100 further comprises a rear end 111 defining a rear wall 116 opposite the front end 108. The top rail 110, sole 112, heel 104 and toe 106 extend rearward from the strike face perimeter toward the rear end 111. The rear wall 116 extends upward from the sole 112 at the rear end 111.

In some embodiments, the body material can be a stainless steel, such as 17-4 stainless steel. In other embodiments, the body material can be a steel or stainless steel alloy such as 15-5 stainless steel, 431 stainless steel, 4140 steel, 4340 steel, or any other suitable material. The body material can comprise a density between 7.0 g/cm³ and 10.0 g/cm³. In some embodiments, the body material can comprise a density between 7.0 g/cm³ and 7.5 g/cm³, between 7.5 and 8.0 g/cm³, between 8.0 and 8.5 g/cm³, between 8.5 and 9.0 g/cm³, between 9.0 and 9.5 g/cm³, or between 9.5 and 10.0 g/cm³.

In some embodiments, the strike face is formed as an integral part of the body, such as by unitary casting. In other embodiments, the club head can comprise a separately formed and attached faceplate that forms part or all of the strike face. The faceplate can be coupled to the body via welding or any other suitable means. The faceplate can be formed from a similar or different material than the body material. In some embodiments, the faceplate material can be a higher strength material than the body material. In many embodiments, the faceplate material can be a maraging steel such as C300. In other embodiments, the faceplate material can be a high-strength steel or steel alloy, C250, C350, AerMet® 100, AerMet® 310, AerMet® 340, HSR300, K300 or any other high-strength material suitable of being formed into a faceplate.

Referring now to FIG. 5, the iron-type golf club head 100 further comprises a cavity 125 at least partially enclosed by the club head body 101. Interior surfaces of the strike face 102, the top rail 110, the sole 112, the rear wall 116, the heel 104, and/or the toe 106 can at least partially define one or more cavity walls forming the boundary of the cavity 125. For example, the club head 100 includes a strike face rear surface 115, a top rail interior surface 119, a sole interior surface 121, a rear wall interior surface 123, a heel interior surface, and/or a toe interior surface at least partially forming the boundary of the cavity 125. In the illustrated embodiment of FIG. 5, the rear wall 116 extends all the way from the sole 112 to the top rail 110, thereby enclosing a hollow interior cavity 125 in combination with the remainder of the body 101. Such embodiments can be referred to as a “fully enclosed hollow-body” club head.

In other embodiments, such as the illustrated embodiment of FIGS. 9 and 10, the rear wall 216 can extend only partially between the sole 212 and the top rail 210 and forms a rear opening 222 that fluidly communicates with the club head exterior. In some embodiments, the rear opening 222 is uncovered, thereby creating an open cavity 225 exposed to the club head exterior. Such embodiments can be referred to as a “cavity-back” club head. In other embodiments (described and illustrated in further detail below), the rear opening can be covered by a badge, cover, and/or other member, whereby the rear wall and said covering member combine to enclose a hollow interior cavity. In such embodiments, the club head can be referred to as a “capped hollow-body” club head.

In some embodiments, the badge (or cover) can be formed of a lightweight metal material, including, but not limited to, aluminum or an aluminum alloy. In other embodiments, the badge can comprise a lightweight polymer, a plastic material, or a composite material. In some embodiments, the badge is constructed from multiple materials. In some embodiments, the badge comprises a density less than the density of the club head body.

Any of the pneumatic insert embodiments described herein can be applied to any of the open cavity and/or hollow interior cavity embodiments described herein. Specific club head embodiments and cavity configurations are described in greater detail below. The term “cavity” as used herein, unless otherwise specified, can refer to a hollow interior cavity, enclosed either entirely or partially by the club head body, or an open cavity that fluidly communicates with the exterior of the club head. The term “cavity-back” can refer to a club head comprising an open cavity 225 with an uncovered rear opening. The term “fully enclosed hollow-body” can refer to a club head comprising a hollow interior cavity that is fully or substantially enclosed by the club head body.

The “ground plane,” as used herein, refers to a reference plane associated with the surface on which a golf ball is placed. The ground plane 1010 can be a horizontal plane tangent to the sole 112 at an address position (i.e., wherein the club head 100 is oriented at its intended loft angle and lie angle). The ground plane 1010 is illustrated in FIGS. 3 and 4.

The term “strike face perimeter,” as used herein, can refer to an edge of the strike face. The strike face perimeter can be located along an outer edge of the strike face where the curvature deviates from being planar.

The “geometric center” of the strike face, as used herein, refers to a geometric center point of the strike face perimeter. In the same or other examples, the geometric center point also can be centered with respect to an engineered impact zone or scoring area (defined below), which can be defined by a region of grooves on the strike face. As another approach, the geometric center point of the strike face can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA). The geometric center of the strike face can also be referred to as the “strike face center.”

Further, referring to FIG. 3, the iron-type golf club head 100 can comprise a scoring area occupied by a plurality of score lines 117. The scoring area comprises a scoring area heel-side boundary plane 1020 tangent to the heel-most extent of the plurality of score lines 117 and a scoring area toe-side boundary plane 1025 tangent to the toc-most extent of the plurality of score lines 117. The scoring area heel-side boundary plane 1020 and the scoring area toc-side boundary plane 1025 each extend parallel to the YZ plane. The scoring area is bounded by the scoring area heel-side boundary plane 1020, the scoring area toe-side boundary plane 1025, and the strike face perimeter.

Physical characteristics of the club head 100 can be described relative to reference points defined by the club head 100 or surrounding environment. For example, as illustrated in FIGS. 3 and 4, the club head 100 can define a primary coordinate system centered about the strike face geometric center 120. The primary coordinate system can comprise an X-axis 1040, a Y-axis 1050, and a Z-axis 1060. The X-axis 1040 can extend in a heel-to-toc direction, and is parallel to the ground plane 1010. The X-axis 1040 can be positive towards the heel 104 and negative towards the toe 106. The Y-axis 1050 can extend in a top rail-to-sole direction and is orthogonal to both the ground plane 1010 and the X-axis 1040. The Y-axis 1050 can be positive towards the top rail 110 and negative towards the sole 112. The Z-axis 1060 can extend in front-to-rear direction and is parallel to the ground plane 1010 and orthogonal to both the X-axis 1040 and the Y-axis 1050. The Z-axis 1060 can be positive towards the strike face 102 and negative towards the rear end 111.

The primary coordinate system, as described herein, defines an XY plane extending through the X-axis 1040 and the Y-axis 1050. The coordinate system defines an XZ plane extending through the X-axis 1040 and the Z-axis 1060. The coordinate system further defines a YZ plane extending through the Y-axis 1050 and the Z-axis 1060. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the coordinate system origin located at the strike face geometric center 120. In these or other embodiments, the golf club head 100 can be viewed from a front view when the strike face 102 is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club head can be viewed from a side view or side cross-sectional view when the heel 104 is viewed from a direction perpendicular to the YZ plane.

The “center of gravity” or “CG” of the club head, as described herein, can refer to the point at which the mass is centered within the club head. The term or phrase “center of gravity position” or “CG location” can refer to the location of the club head center of gravity (CG) with respect to the XYZ coordinate system, wherein the CG position is characterized by locations along the X-axis 1040, the Y-axis 1050, and the Z-axis 1060. The term “CG_X” can refer to the CG location along the X-axis 1040, measured from the strike face geometric center 120. The term “CG height” can refer to the CG location along the Y-axis 1050, measured from the strike face geometric center 120. The term “CG_Y” can be synonymous with the CG height. The term “CG depth” can refer to the CG location along the Z-axis 1060, measured from the strike face geometric center 120. The term “CG_Z” can be synonymous with the CG depth.

The golf club head 100 further comprises a coordinate system centered about the center of gravity 160. The coordinate system comprises an X′-axis 1070, a Y′-axis 1080, and a Z′-axis 1090. The X′-axis 1070 extends in a heel-to-toe direction. The X′-axis is positive towards the heel 104 and negative towards the toe 106. The Y′-axis 1080 extends in a sole-to-top rail direction and is orthogonal to both the ground plane 1010 and the X′-axis 1040. The Y′-axis 1080 is positive towards the top rail 110 and negative towards the sole 112. The Z′-axis 1090 extends in a front-to-rear direction, parallel to the ground plane 1010 and orthogonal to both the X′-axis 1070 and the Y′-axis 1080. The Z′-axis 1090 is positive towards the strike face 102 and negative towards the rear end 111.

The term or phrase “moment of inertia” (hereafter “MOI”) can refer to a value derived using the center of gravity (CG) location. The term “MOI_xx” or “I_xx” can refer to the MOI measured about the X′-axis 1070. The term “MOI_YY” or “I_yy” can refer to the MOI measured about the Y′-axis 1080. The term “MOI_ZZ” or “I_zz” can refer to the MOI measured about the Z′-axis 1090. The MOI values MOI_XX, MOI_YY, and MOI_ZZ determine how forgiving the club head 100 is for off-center impacts with a golf ball.

Various manufacturing techniques can be used to form the pneumatic insert. For example, the term “vacuum forming” as used herein refers to a thermoforming method in which a material is heated to a softening point, enabling the material to be stretched in a sheet or thin layer over a mold. A vacuum force is then applied to pull the air out from between the material and the mold such that the sheet is forced against the mold. The material is then allowed to cool or forcibly cooled to a solid state to retain the geometry of the mold.

The term “pressure forming” as used herein refers to a thermoforming method in which a material is heated to a softening point. The material is stretched in a sheet or thin layer over a mold. A vacuum force is applied to pull the air out from between the material and the mold such that the sheet is forced against the mold. A pressing tool is further applied to the side of the material opposite the mold.

The term “mechanical forming” or “plug-assist forming” as used herein refers to a thermoforming method in which a material is heated to a softening point. The material is stretched in a sheet or thin layer over a negative mold. A core plug forces the pliable sheet into the negative mold. In mechanical forming, no positive or negative air pressure is applied to the sheet material.

The term “drape forming” as used herein refers to a thermoforming method in which a material is heated to a softening point. The material is stretched in a sheet or thin layer. The material is then draped over mandrels and lowered onto a mold. A vacuum force can be applied to further stretch the material over the mold geometry.

The term “matched mold forming” as used herein refers to a thermoforming method in which a material is heated to a softening point. The material is stretched in a sheet or thin layer between complementary male and female molds. The molds are pressed against each other such that the material takes the pattern or shape designed onto the molds.

The term “twin sheet forming” as used herein refers to a thermoforming method in which two or more sheets or layers of material are heated to a softening point, held separate from each other through a clamping means, and at least partially pressed together from both a top and bottom side with male and female molds. This process is often used to form a hollow interior in the initial space of separation between the two or more layers of material.

The term “billow forming” as used herein refers to a free-form thermoforming method in which a material is heated to a softening point. The material is stretched in a sheet or thin layer, and inflated with an air pressure.

DESCRIPTION

Described herein are various embodiments of an iron-type golf club head comprising a pneumatic insert. The pneumatic insert improves club head sound and feel by damping dominant impact vibrations. The pneumatic insert resides within the club head cavity and damps vibrations by contacting and/or providing pressure against one or more club head interior surfaces. The pneumatic insert comprises a membrane enclosing one or more hollow chambers. The one or more hollow chambers are filled with a pressurized gas.

In addition to damping impact vibrations, the pneumatic insert can structurally reinforce the strike face. The pneumatic insert applies a reinforcing pressure to the strike face rear surface so that the thickness of the strike face can be reduced to increase strike face flexure and ball speed without sacrificing durability. The pneumatic insert design can therefore improve both the club head vibrational response and strike face flexure. The insert pressure, insert contact area, membrane material, membrane thickness, and presence or absence of reinforcing structures or weight members influence the vibrational response and club head flexibility. As such, the pneumatic insert design and the strike face thickness profile can be combined to improve vibration damping, strike face support, and ball speed.

The hollow nature of the pneumatic insert reduces mass in comparison to a solidly constructed insert or a solid filler material with an equal vibration damping effect. As such, the pneumatic insert damps vibrations and improves sound and feel while increasing discretionary mass, thereby improving club head mass properties and ball flight performance. Further, in some embodiments, the pneumatic insert is secured within the interior cavity and/or located in a desired position by one or more retainers. Unlike prior art damping systems, the retainers lack the robustness that takes up significant amounts of discretionary mass and offsets the weight savings of the pneumatic insert.

The one or more retainers can comprise one or more club head retainers that are disposed to the interior cavity. The one or more club head retainers can be lightweight, integral club head body features specifically designed for securing the pneumatic insert within the cavity, such as one or more protrusions, juts, ledges, shelves, rails, bumpers, grooves, channels, trenches, indentations, or recesses. In other embodiments, the one or more club head retainers can be one or more internal club head geometries, such as an internal mass pad forming an undercut (described in detail below). Such club head retainers can locate mass in advantageous locations in addition to securing the pneumatic insert within the cavity. In some embodiments, the one or more club head retainers can be formed as separate members attached to the club head body. For example, in some embodiments, the club head can comprise a mass pad formed as an integral part of the club head body. In other embodiments, all or a portion of the mass pad can be a separately formed and attached weight member comprising a similar or different material than the body material. In some embodiments, the mass pad can comprise a higher density material than the body material to concentrate mass in a desired location.

In some embodiments, the one or more retainers can comprise one or more insert retainers provided on the pneumatic insert. The one or more insert retainers can be one or more of the group consisting of ribs, protrusions, extensions, solid portions, geometries, fasteners, slots, grooves, recesses, weight members, or other suitable members formed integrally with or separately attached to the pneumatic insert. In some embodiments, the insert shaping and/or dimensions can serve as insert retainers. For example, in some embodiments, the pneumatic insert can be asymmetrically shaped to prevent it from moving around the cavity during use. The one or more insert retainers can engage one or more of the club head retainers to secure the pneumatic insert. In some embodiments, one or more insert retainers are shaped correspondingly or oppositely to one or more club head retainers.

In some embodiments, the club head comprises multiple pneumatic inserts. The multiple pneumatic inserts can accommodate complex cavity geometries and increase insert contact area. The multiple pneumatic inserts can also allow for varying damping and performance characteristics across the club head. Customization of the cavity geometry and insert placement therein is contemplated by the embodiments below.

In some embodiments, the club head comprises a localized pneumatic insert that does not occupy the entirety of the cavity. The localized pneumatic insert can be strategically shaped and positioned to damp high-vibration areas of the club head. As such, the localized pneumatic insert can efficiently damp vibrations while creating discretionary mass over a similar insert occupying the entire cavity. In some embodiments, the localized pneumatic insert contacts only a portion of the club head interior surfaces.

I. General Section

A. Pneumatic Insert

The club head comprises a pneumatic insert disposed within the cavity to control vibrations and improve the sound and feel of the club head. The pneumatic insert is a pressurized, hollow insert comprising a membrane constructed of a flexible, moldable, and/or formable material and filled with air or another suitable gas. The pneumatic insert occupies at least a portion of the cavity. In some embodiments, the pneumatic insert comprises an insert retainer configured to engage a club head retainer and secure the pneumatic insert within the cavity. In some embodiments, the pneumatic insert can be molded or otherwise formed to conform to the shape of the cavity. The pneumatic insert contacts one or more club head interior surfaces, thereby damping club head vibrations. As discussed in further detail below, the insert pressure, size, shape, membrane material, and location within the cavity influence the insert's damping characteristics.

As illustrated in FIGS. 6 and 7, the pneumatic insert 140 comprises a membrane 142 enclosing a hollow chamber 144. The hollow chamber 144 is filled with a pressurized gas, such as pressurized air or another suitable gas. The hollow nature of the pneumatic insert 140 creates discretionary mass over a solidly constructed insert or filler material. The pneumatic insert comprises an insert top end 161, and insert bottom end 162, an insert heel end 163, an insert toe end 164, an insert forward surface 146, and an insert rear surface 148. When installed, as illustrated in FIG. 6, the pneumatic insert 140 is configured such that the insert top end 161 is disposed to the top rail 110; the insert bottom end 162 is disposed to the sole 112; the insert heel end 163 is disposed to the heel 104; the insert toe end 164 is disposed to the toe 106; the insert forward surface 146 is disposed to the strike face 102; and the insert rear surface 148 is disposed to the rear wall 116.

The membrane material is selected based on multiple factors, such as durability, ability to retain pressurized gas, and case of manufacture. The membrane 142 can comprise a moldable, formable, deformable, or flexible material. In some embodiments, the membrane material allows the membrane 142 to be pre-formed to a desired depressurized shape and subsequently inflated to a desired pressurized shape. In some embodiments, the membrane material allows the pneumatic insert 140 to deform during use, such that club head flexibility and ball speed are not hindered. The membrane material can be selected to achieve a suitable shape through forming, to comprise specific properties, or to provide the pneumatic insert 140 with a desired flexibility at a certain insert pressure.

In some embodiments, the membrane 142 comprises a thermoplastic or polymeric material. In some embodiments, the membrane comprises a thermoplastic rubber, thermoplastic polyurethane (TPU), or a thermoplastic polyester elastomer (TPE). In some embodiments, the membrane comprises a fluroelastomer, a polyethylene, polypropylene (PP), polystyrene (PS), polyethylene terephthalate (PET), low-density polyethylene LDPE), high-density polyethylene (HDPE), polyvinyl chloride (PVC), polycarbonate (PC), cellulose acetate, polymethyl methacrylate (PMMA), acrylonitrile-butadiene-styrene (ABS), styrene rubber, natural rubber, silicone rubber, sulfide rubber, or a butyl rubber. In some embodiments, the membrane material can comprise a resilient, thermoplastic, elastomeric barrier film, polyether polyurethanes (such as cast or extruded ester based polyurethane films, e.g., Tetra Plastics TPW-250); thermoplastic urethanes, thermoplastic urethanes based on polyesters, polyethers, polycaprolactone, and polycarbonate macrogels; thermoplastic films containing crystalline material thermoplastic urethanes based on polyesters, polyethers, polycaprolactone, and polycarbonate macrogels; thermoplastic films containing crystalline material, polyurethane including a polyester polyol, or multi-layer films formed of at least one elastomeric thermoplastic material layer and a barrier material layer formed of a copolymer of ethylene and vinyl alcohol. In some embodiments, the membrane material can be any other suitable material not explicitly enumerated above. The membrane material can be selected based on the desired flexibility of the membrane, the desired membrane forming properties, and/or the desired club head vibration damping properties. In some embodiments, the membrane 142 can comprise a plurality of layers. In such embodiments, one or more of the plurality of layers can comprise any one material or combination of materials selected from the group above.

The membrane material can be selected to provide the desired damping effect and flexibility at a relatively low density. In some embodiments, the membrane 142 comprises a low-density material, thereby reducing the pneumatic insert mass. In some embodiments, the membrane material density can be between 0.5 and 3.0 g/cm³. In some embodiments, the membrane material density can be between 0.5 and 0.75 g/cm³, between 0.75 and 1.0 g/cm³ between 1.0 and 1.25 g/cm³, between 1.25 and 1.50 g/cm³, between 1.50 and 1.75 g/cm³, between 1.75 and 2.00 g/cm³, between 2.00 and 2.25 g/cm³, between 2.25 and 2.50 g/cm³, between 2.50 and 2.75 g/cm³, or between 2.75 and 3.0 g/cm³. In some embodiments, the membrane material density can be less than 3.0 g/cm³, less than 2.75 g/cm³, less than 2.50 g/cm³, less than 2.25 g/cm³, less than 2.0 g/cm³, less than 1.75 g/cm³, less than 1.5 g/cm³, less than 1.25 g/cm³, less than 1.0 g/cm³, less than 0.75 g/cm³, or less than 0.5 g/cm³.

As described above, the flexible material aids in the damping of undesirable vibrations and allows the membrane 142 to be pre-formed to a desired depressurized shape and subsequently inflated to a desired pressurized shape. This flexibility is in part due to the low elastic modulus of elasticity of the membrane 142. In some embodiments, the membrane 142 comprises a low-modulus material. In some embodiments, the membrane material elastic modulus can between 0.5 and 6.0 GPa. In some embodiments, the membrane material elastic modulus can between 0.5 and 1.0 GPa, between 1.0 and 2.0 GPa, between 2.0 and 3.0 GPa, between 3.0 and 4.0 GPa, between 4.0 and 5.0 GPa, or between 5.0 and 6.0 GPa. In some embodiments, the membrane material elastic modulus can be less than 6.0 GPa, less than 5.0 GPa, less than 4.0 GPa, less than 3.0 GPa, less than 2.0 GPa, less than 1.0 GPa, or less than 0.5 GPa.

As illustrated in FIG. 7, the membrane 142 comprises a membrane thickness tm measured from a membrane outer surface 147 to a membrane inner surface 149. In some embodiments, the membrane thickness ty can range between 0.001 inch and 0.100 inch. In some embodiments the membrane thickness ty can be between 0.001 inch and 0.005 inch, between 0.005 inch and 0.010 inch, between 0.010 inch and 0.015 inch, between 0.015 inch and 0.020 inch, between 0.020 inch and 0.025 inch, between 0.025 inch and 0.030 inch, between 0.030 inch and 0.035 inch, between 0.035 inch and 0.040 inch, 0.040 inch and 0.045 inch, between 0.045 inch and 0.050 inch, between 0.050 inch and 0.055 inch, between 0.055 inch and 0.060 inch, between 0.060 inch and 0.065 inch, between 0.065 inch and 0.070 inch, between 0.070 inch and 0.075 inch, between 0.075 inch and 0.080 inch, between 0.080 inch and 0.085 inch, between 0.085 inch and 0.090 inch, between 0.090 inch and 0.095 inch, or between 0.095 and 0.100. In some embodiments, the membrane thickness ty can be greater than 0.001 inch, greater than 0.005 inch, greater than 0.010 inch, greater than 0.015 inch, greater than 0.020 inch, greater than 0.025 inch, greater than 0.030 inch, greater than 0.035 inch, greater than 0.040 inch, greater than 0.045 inch, greater than 0.050 inch, greater than 0.055 inch, greater than 0.060 inch, greater than 0.065 inch, greater than 0.070 inch, greater than 0.075 inch, greater than 0.080 inch, greater than 0.085 inch, greater than 0.090 inch, greater than 0.095 inch, or greater than 0.100 inch. In some embodiments, the membrane thickness ty can be less than 0.100 inch, less than 0.090 inch, less than 0.080 inch, less than 0.070 inch, less than 0.060 inch, less than 0.050 inch, less than 0.040 inch, less than 0.030 inch, less than 0.020 inch, or less than 0.010 inch.

In some embodiments, the membrane thickness ty is uniform across the entirety of the membrane 142. In other embodiments, the membrane thickness ty can be variable such that certain regions of the membrane 142 can comprise a greater thickness than other regions. The selected membrane thickness ty can depend on the membrane material and the desired pressure of the pneumatic insert. The membrane 142 must be sufficiently thick to be durable throughout use of the golf club head 100, without being so thick that the pneumatic insert 140 is too heavy or hinders club head flexibility. In embodiments wherein the pneumatic insert 140 is exposed to the club head exterior, the membrane 142 may comprise a greater membrane thickness ty than that of a pneumatic insert 140 that is concealed and protected within a hollow interior cavity. A sufficient membrane thickness ty can protect an exposed pneumatic insert 140 from puncture.

In some embodiments, the membrane 142 comprises a single-piece, unitary construction. In some embodiments, the membrane 142 can comprise a multi-piece assembly. Two or more membrane components can be separately formed and sealed together through heat, adhesive, epoxy, mechanical means, or any other suitable connection method. The membrane components can comprise complementary geometries to one another, such that the membrane components align to form an air-tight chamber when sealed together. In some embodiments, forming a multi-piece membrane 142 can enable manufacturability of complex membrane geometries.

In some embodiments, the membrane 142 can comprise multiple layers. The plurality of layers can be the same material or different materials. In some embodiments comprising a multi-layered membrane, each layer can be formed individually. In such embodiments, each layer can be pressurized separately to abut an adjacent layer or to create a gap between adjacent layers. In other embodiments comprising a multi-layered membrane, the plurality of layers can be formed together, forming a unitary, layered membrane.

The chamber 144 is filled with one or more pressurized gases. In some embodiments, the chamber 144 is filled with air. In some embodiments, the chamber 144 is filled with an inert gas or any other suitable gas. In some embodiments, the chamber 144 is filled with a large-molecule gas to prevent gas molecules from permeating through the membrane 142 and lowering the insert pressure. In some embodiments, the pressurized gas can be oxygen; nitrogen; argon; hexafluoroethane; sulfur hexafluoride; perfluoropropane;

perfluorobutane; perfluoropentane; perfluorohexane; perfluoroheptane; octafluorocyclobutane; perfluorocyclobutane; hexafluoropropylene; tetrafluoromethane; monochloropentafluoroethane; 1, 2-dichlorotetrafluoroethane; 1, 1, 2-trichloro-1, 2, 2 trifluoroethane; chlorotrifluoroethylene; bromotrifluoromethane; or monochlorotrifluoromethane. In some embodiments, the chamber 144 can be filled with any combination or mixture of the gases listed above. In some embodiments, rather than being filled with gas, the chamber 144 can be fully or partially filled with a liquid, a gel, or any other suitable fluid.

The thin, low-density membrane 142 and the hollow chamber 144 create a substantially lightweight pneumatic insert 140 that damps vibrations and provides structural reinforcement, all while preserving club head discretionary mass. In some embodiments, the pneumatic insert 140 comprises an insert mass between 0.5 and 10 grams. In some embodiments, the insert mass can be between 0.5 and 5 grams, between 1.0 and 6.0 grams, between 2.0 and 7.0 grams, between 3.0 and 8.0 grams, between 4.0 and 9.0 grams, or between 5.0 and 10.0 grams. In some embodiments, the insert mass can be less than 10.0 grams, less than 9.0 grams, less than 8.0 grams, less than 7.0 grams, less than 6.0 grams, less than 5.0 grams, less than 4.0 grams, less than 3.0 grams, less than 2.0 grams, or less than 1.0 gram. In some embodiments, the insert mass can be approximately 1.0 gram, 2.0 grams, 3.0 grams, 4.0 grams, 5.0 grams, 6.0 grams, 7.0 grams, 8.0 grams, 9.0 grams, or 10.0 grams.

The chamber 144 comprises a fully-inflated chamber volume. In some embodiments, the chamber volume can be between 1.0 cm³ and 30.0 cm³. In some embodiments, the chamber volume can be between 1.0 and 5.0 cm³, between 5.0 and 10.0 cm³, between 10.0 and 15.0 cm³, between 15.0 and 20.0 cm³, between 20.0 and 25.0 cm³, or between 25.0 and 30.0 cm³. In some embodiments, the chamber volume can be greater than 1.0 cm³, greater than 5.0 cm³, greater than 10.0 cm³, greater than 15.0 cm³, greater than 20.0 cm³, greater than 25.0 cm³, or greater than 30.0 cm³. In some embodiments, the chamber volume can be less than 30.0 cm³, less than 25.0 cm³, less than 20.0 cm³, less than 15.0 cm³, less than 10.0 cm³, less than 5.0 cm³, or less than 1.0 cm³.

The pneumatic insert 140 comprises an insert pressure that provides the desired damping effect and club head flexibility. The insert pressure can be defined as the pressurized gas “gauge pressure,” measured relative to the ambient pressure. In some embodiments, the insert pressure can be greater than or equal to the ambient pressure. Specifically, the pressure inside the pneumatic insert can be between 0 psi and 30 psi. In some embodiments, the insert pressure can be between 0 and 5 psi, between 5 and 10 psi, between 10 and 15 psi, between 15 and 20 psi, between 20 and 25 psi, or between 25 and 30 psi. In some embodiments, the insert pressure can be between 0 psi and 5.0 psi. In some embodiments, the insert pressure can be between 0 and 1.0 psi, between 0.5 and 1.5 psi, between 1.0 and 2.0 psi, between 1.5 and 2.5 psi, between 2.0 and 3.0 psi, between 2.5 and 3.5 psi, between 3.0 and 4.0 psi, between 3.5 and 4.5 psi, or between 4.0 and 5.0 psi. In some embodiments, the insert pressure can be greater than 0 psi, greater than 0.5 psi, greater than 1.0 psi, greater than 1.5 psi, greater than 2.0 psi, greater than 2.5 psi, greater than 3.0 psi, greater than 3.5 psi, greater than 4.0 psi, greater than 4.5 psi, or greater than 5.0 psi. In some embodiments, the insert pressure can be approximately 0.5 psi, 1.0 psi, 1.5 psi, 2.0 psi, 2.5 psi, 3.0 psi, 3.5 psi, 4.0 psi, 4.5 psi, or 5.0 psi.

The insert pressure impacts both the flexibility of the pneumatic insert and the membrane thickness. The membrane material thins as it is pressurized and molds to its surrounding structure. As such, a higher insert pressure results in the membrane stretching further across the surrounding structure. This results in a thinner, but more intricate, geometry for the hollow membrane. Further, the membrane material will impact the amount of pressure that needs to be applied to fully mold the hollow membrane as described.

In some embodiments, rather than comprising a single chamber within the membrane, the pneumatic insert can be segmented to form a plurality of sub-chambers within the overall chamber. Segmenting the pneumatic insert can vary club head damping and performance characteristics. FIGS. 8A-8D illustrate embodiments of a pneumatic insert 140 comprising multiple sub-chambers 166. The pneumatic insert 140 can comprise one or more inner walls 165 dividing the overall chamber into a plurality of sub-chambers 166. The one or more inner walls 165 can extend across the chamber, with either end of a given inner wall 165 connecting to the membrane 142. The sub-chambers 166 allow localized pressure control across different areas of the pneumatic insert 140. In some embodiments, one or more of the sub-chambers 166 can be filled with the same pressurized gas. In other embodiments, one or more of the sub-chambers 166 can be filled with different pressurized gases. In some embodiments, the plurality of sub-chambers 166 can comprise similar geometries, such that the inner walls 165 form a repeating pattern of sub-chambers 166. In other embodiments, one or more of the plurality of sub-chambers 166 can comprise different geometries. The plurality of sub-chambers 166 can be configured improve club head damping and flexure.

In some embodiments, one or more of the sub-chambers 166 can comprise the same insert pressure. In other embodiments, one or more of the sub-chambers 166 can comprise different insert pressures. In some embodiments, one or more of the sub-chambers 166 can comprise a greater insert pressure than one or more of the other sub-chambers 166 to locally stiffen or damp vibrations in a certain portion of the club head. In some embodiments, increasing the insert pressure of one or more sub-chambers 166 can allow a corresponding portion of the strike face to be thinned. Any of the sub-chambers 166 described in the embodiments below can comprise an insert pressure greater than or less than any other sub-chamber 166.

In some embodiments, the membrane 140 can integrally form the inner walls 165. In other embodiments, the inner walls 165 can be separately formed and attached to the membrane 140 and/or formed from a material other than the membrane material. As illustrated in FIG. 8A, the one or more inner walls 165 can comprise an inner wall thickness t_IW measured between opposing inner wall surfaces. In some embodiments, the inner wall thickness t_IW of one or more of the inner walls 165 can be substantially similar to the membrane thickness tm described above. In other embodiments, the inner wall thickness t_IW of one or more of the inner walls 165 can be less than the membrane thickness t_M. In some embodiments, one or more of the inner walls 165 can comprise the same thickness t_IW. In other embodiments, one or more of the inner walls 165 can comprise different thicknesses t_IW.

FIG. 8A illustrates a pneumatic insert 140 comprising a vertical inner wall 165a extending through the chamber from an insert top end 161 to an insert bottom end 162. The vertical inner wall 165a divides the chamber into a heel-side sub-chamber 166a and a toe-side sub-chamber 166b.

FIG. 8B illustrates a pneumatic insert 140 comprising a horizontal inner wall 165b extending through the chamber from an insert heel end 163 to an insert toe end 163. The horizontal inner wall 165b divides the chamber into a top sub-chamber 166c and a bottom sub-chamber 166d.

FIG. 8C illustrates a pneumatic insert 140 comprising both a vertical inner wall 165a and a horizontal inner wall 165b. The vertical inner wall 165a and the horizontal inner wall 165b intersect one another near the center of the chamber. The vertical inner wall 165a and the horizontal inner wall 165b divide the cavity into four sub-chambers: a top heel-side sub-chamber 166e, a top toe-side sub-chamber 166f, a bottom heel-side sub-chamber 166g, and a bottom toe-side sub-chamber 166h.

FIG. 8D illustrates a pneumatic insert 140 comprising a plurality of diagonal inner walls extending through the chamber. Specifically, the pneumatic insert 140 includes a first diagonal inner wall 165c extending from the insert top end 161 to the insert heel end 163, a second diagonal inner wall 165d extending from the insert top end 161 to the insert toe end 164, a third diagonal inner wall 165e extending from the insert bottom end 162 to the insert heel end 163, and a fourth diagonal inner wall 165f extending from the insert bottom end 162 to the insert toe end 164. The plurality of diagonal inner walls 165c, 165d, 165c, 165f form a diamond shaped perimeter surrounding a center sub-chamber 166i. The pneumatic insert 140 illustrated in FIG. 8D comprises four sub-chambers surrounding the center sub-chamber 166i. The first diagonal inner wall 165c separates the center sub-chamber 166i from a top heel-side sub-chamber 166e. The second diagonal inner wall 165d separates the center sub-chamber 166i from a top toc-side sub-chamber 166f. The third diagonal inner wall 165e separates the center sub-chamber 166i from a bottom heel-side sub-chamber 166g. The fourth diagonal inner wall 165f separates the center sub-chamber 166i from a bottom toe-side sub-chamber 166h. In some embodiments, the center sub-chamber 166i is located directly behind the strike face geometric center. The center sub-chamber 166i allows the insert pressure to be controlled directly behind the strike face geometric center, thereby influencing strike face vibration and flexure characteristics. In some embodiments, the center sub-chamber 166i comprises a lesser insert pressure than the top heel-side sub-chamber 166e, the top toe-side sub-chamber 166f, the bottom heel-side sub-chamber 166g, and the bottom toe-side sub-chamber 166h. In such embodiments the pneumatic insert 140 increases strike face flexibility. In other embodiments, the enter sub-chamber 166i comprises a greater insert pressure than the top heel-side sub-chamber 166c, the top toe-side sub-chamber 166f, the bottom heel-side sub-chamber 166g, and the bottom toe-side sub-chamber 166h. In such embodiments, the pneumatic insert 140 can increase vibration damping near the strike face geometric center and allow the strike face to be thinned.

Although FIGS. 8A-8D illustrate various embodiments of pneumatic inserts 140 comprising a plurality of sub-chambers 166, the sub-chamber configurations and inner wall configurations are not limited to the embodiments above. In some embodiments, the pneumatic insert can comprise two, three, four, five, six, seven, eight, nine, ten, or any number of sub-chambers. In some embodiments, the pneumatic insert can comprise any number or combination of interior walls extending vertically, horizontally, diagonally, in an arcuate manner, or any other configuration.

In some embodiments, the pneumatic insert can comprise a valve providing selective access through the membrane and into the chamber. The valve can be configured to receive an inflation needle (or other inflation apparatus) and seal the membrane when no inflation needle is present. In such embodiments, the insert pressure can be controlled by inflating the insert via the inflation needle or by releasing gas through the valve to deflate the pneumatic insert. In some embodiments, the pneumatic insert can comprise a duckbill valve, an umbrella valve, a Belleville valve, a duckbill-umbrella combination valve, an X-fragm valve, minivalveballs, cross-slit valves, dome valves, or any other suitable valve type. In some embodiments, the pneumatic insert can comprise any combination of the valve types listed above.

Any of the pneumatic insert embodiments described herein can comprise any of the valves described above. Further, the pneumatic insert comprising a valve can be applied to any club type described above, including a cavity-back club head, a capped hollow-body club head, or a fully enclosed hollow body Alternatively, any of the pneumatic insert embodiments described herein can be devoid of a valve. In some embodiments, the pneumatic insert can comprise a sacrificial valve that is trimmed after inflation and permanently sealed prior to the pneumatic insert is installed. In some embodiments, the membrane can be directly punctured by an inflation needle or other inflation apparatus and subsequently sealed. The point of puncture can be sealed via heat sealing, a patch, a self-sealing material, or an alternative covering.

B. Club Head/Insert Relationships

The pneumatic insert can provide the desired vibrational and performance benefits while increasing discretionary mass. Although the pneumatic insert illustrated in certain embodiments may be shown as occupying the entire cavity, in some embodiments, the pneumatic insert may occupy only a portion of the cavity volume (i.e., the volume bounded by the cavity-forming interior surfaces). The pneumatic insert can be configured to pinpoint high-vibration areas, thereby providing the desired damping effect with less mass. A smaller pneumatic insert that only partially occupies the cavity can have several benefits. A smaller pneumatic insert can create discretionary mass over a larger pneumatic insert. In cavity-back or capped hollow-body embodiments, a smaller pneumatic insert can fit within a smaller rear opening, allowing the pneumatic insert to be secured within the cavity by a small, lightweight covering means or badge. In some embodiments, a smaller pneumatic insert can be configured to contact portions of the club head body where vibration damping or structural reinforcement are desired, but not portions where club head flexibility might be hindered.

In some embodiments, the pneumatic insert can occupy between 10% and 100% of the cavity volume. In some embodiments, the pneumatic insert can occupy 10% and 25%, between 25% and 50%, between 50% and 75%, or between 75% and 100% of the cavity volume. In some embodiments, the pneumatic insert can occupy between 10% and 20%, between 20% and 30%, between 30% and 40%, between 40% and 50%, between 50% and 60%, between 60% and 70%, between 70% and 80%, between 80% and 90%, or between 90% and 100% of the cavity volume. In some embodiments, the pneumatic insert can occupy greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 95% of the cavity volume. In some embodiments, the pneumatic insert can occupy less than 95%, less than 90%, less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, or less than 10% of the cavity volume. In some embodiments, the pneumatic insert can occupy approximately 10%, 11%, 12%, 13%, 14%, 15%, 16%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of the cavity volume.

As described above, the pneumatic insert damps club head vibrations by contacting one or more club head interior surfaces. In some embodiments, the pneumatic insert can contact all of the club head interior surfaces. In other embodiments, the pneumatic insert can contact only select club head interior surfaces or can only contact portions of a given club head interior surface. The contact area between the pneumatic insert and the club head interior surfaces as well as which interior surfaces the pneumatic insert contacts influence the club head vibrational response. Contact between the pneumatic insert and the club head interior surfaces restricts the vibration of said surfaces. In general, club head vibrations are most effectively dampened in areas contacted by the pneumatic insert, and a greater overall contact area between the pneumatic insert and club head interior surfaces improves the overall club head vibrational response. However, a greater contact area between the pneumatic insert and club head interior surfaces can also restrict club head flexure, especially in club head areas contacted by the pneumatic insert. If the pneumatic insert excessively restricts club head flexure, ball speed will be lost. In some embodiments, the pneumatic insert contacts only portions of the club head interior surfaces, to balance vibration damping with club head flexibility.

The pneumatic insert can contact at least a portion of the strike face rear surface, the sole interior surface, the top rail interior surface, the heel interior surface, the toe interior surface, the rear wall interior surface, or any combination thereof. In some embodiments, the pneumatic insert can be configured such that it does not contact any portion of the strike face rear surface, the sole interior surface, the top rail interior surface, the heel interior surface, the toe interior surface, the rear wall interior surface, or any combination thereof.

The club head defines an insert contact area as the club head interior surface area that is contacted by the pneumatic insert. In some embodiments, the insert contact area can be between 0.5 and 15.0 in². In some embodiments, the insert contact area can be between 0.5 and 1.0 in², between 1.0 and 2.0 in², between 2.0 and 3.0 in², between 3.0 and 4.0 in², between 4.0 and 5.0 in², between 5.0 and 6.0 in², between 6.0 and 7.0 in², between 7.0 and 8.0 in², between 8.0 and 9.0 in², between 9.0 and 10 in², between 10 and 11 in², between 11 and 12 in², between 12 and 13 in², between 13 and 14 in², or between 14 and 15 in².

The insert contact area can also be expressed as a percentage of the overall club head interior surface area. In some embodiments, the insert contact area can be between 10% and 100% of the club head interior surface area. In some embodiments, the contact area can be between 10% and 25%, between 25% and 50%, between 50% and 75%, or between 75% and 100% of the club head interior surface area. In some embodiments, the contact area can be between 10% and 20%, between 20% and 30%, between 30% and 40%, between 40% and 50%, between 50% and 60%, between 60% and 70%, between 70% and 80%, between 80% and 90%, or between 90% and 100% of the club head interior surface area. In some embodiments, the contact area can be greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 95% of the club head interior surface area. In some embodiments, the contact area can be less than 95%, less than 90%, less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, or less than 10% of the club head interior surface area. In some embodiments, the contact area can be approximately 10%, 11%, 12%, 13%, 14%, 15%, 16%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of the club head interior surface area.

The club head further defines a rear surface contact area as the strike face rear surface area contacted by the pneumatic insert. In some embodiments, the rear surface contact area can be between 0.5 and 7.5 in². In some embodiments, the rear surface contact area can be between 0.5 and 1.0 in², between 1.0 and 2.0 in², between 2.0 and 3.0 in², between 3.0 and 4.0 in², between 4.0 and 5.0 in², between 5.0 and 6.0 in², between 6.0 and 7.0 in², or between 7.0 and 7.5 in².

The rear surface contact area can also be expressed as a percentage of the strike face rear surface area. In some embodiments, the rear surface contact area can be between 25% and 100% of the strike face rear surface area. In some embodiments, the rear surface contact area can be between 25% and 50%, between 50% and 75%, or between 75% and 100% of the strike face rear surface area. In some embodiments, the rear surface contact area can be between 25% and 30%, between 30% and 40%, between 40% and 50%, between 50% and 60%, between 60% and 70%, between 70% and 80%, between 80% and 90%, or between 90% and 100% of the strike face rear surface area. In some embodiments, the rear surface contact area can be greater than 25%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 95% of the strike face rear surface area. In some embodiments, the rear surface contact area can be less than 95%, less than 90%, less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, or less than 25% of the strike face rear surface area. In some embodiments, the rear surface contact area can be approximately 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of the strike face rear surface area. In some embodiments, the pneumatic insert does not contact the strike face rear surface at all. In such embodiments, the rear surface contact area is zero.

In some embodiments, the pneumatic insert occupies only a central portion of the cavity. This configuration reduces the insert mass while still achieving the desired vibration damping characteristics. In such embodiments, the pneumatic insert does not extend all the way between the heel and toe ends of the cavity and does not contact the heel interior surface or the toe interior surface. In some embodiments, referring to FIG. 6, the pneumatic insert 140 can be located substantially behind the scoring area. In such embodiments, the pneumatic insert 140 is entirely or substantially located between the scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. Because the scoring area typically experiences dominant impact vibrations, positioning the pneumatic insert 140 behind the scoring area efficiently damps said vibrations without needing to fill the entire cavity 125.

In some embodiments, between 50% and 100% of the pneumatic insert 140 resides between the scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. In some embodiments, between 50% and 60%, between 60% and 70%, between 70% and 80%, between 80% and 90%, or between 90% and 100% of the pneumatic insert 140 resides between the scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. In some embodiments, greater than 50%, greater than 55%, greater than 60%, greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, or greater than 95% of the pneumatic insert 140 resides between the scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. In some embodiments, 100% of the pneumatic insert resides behind the scoring area, such that no portion of the pneumatic insert 140 extends past the scoring area heel-side boundary plane 1020 or the scoring area toe-side boundary plane 1025.

In some embodiments, the pneumatic insert 140 contacts a large portion of the strike face rear surface 115 behind the scoring area. The club head 100 comprises a scoring area back surface defined as the portion of the strike face rear surface 115 bounded between the scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. In some embodiments, the pneumatic insert 140 contacts a large portion of the scoring area back surface. In some embodiments, the pneumatic insert 140 contacts between 50% and 100% of the scoring area back surface. In some embodiments, the pneumatic insert 140 contacts between 50% and 60%, between 60% and 70%, between 70% and 80%, between 80% and 90%, or between 90% and 100% of the scoring area back surface. In some embodiments, the pneumatic insert 140 contacts greater than 50%, greater than 55%, greater than 60%, greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, greater than 95%, or 100% of the scoring area back surface.

As described above, one or more retainers secures the pneumatic insert within the cavity. Securing the pneumatic insert can refer both to holding the pneumatic insert within the cavity such that it does not fall out during use and retaining the pneumatic insert in an intended location such that it does not change position within the cavity during use. The one or more retainers can mechanically interlock, snap-fit, interference-fit, adhere, or otherwise couple the pneumatic insert to the club head body. Although securing the pneumatic insert may require one or more retainers, said retainers lack the robustness that takes up significant amounts of discretionary mass and offsets the weight savings of the pneumatic insert. The club head body can comprise one or more club head retainers, and the insert can comprise one or more insert retainers. In some embodiments, one or more insert retainers and club head retainers engage one another to secure the pneumatic insert.

The one or more club head retainers can be disposed to the cavity to facilitate engagement with the one or more insert retainers. In some embodiments, the one or more club head retainers can be lightweight, integral club head body features whose primary purpose is to secure the pneumatic insert without using a significant amount of mass. In some embodiments, one or more club head retainers can comprise a protrusion, jut, ledge, shelf, rail, or other suitable feature extending outward from one or more of the club head interior surfaces and into the cavity. In other embodiments, one or more club head retainers can comprise a groove, channel, trench, indentation, recess, or other similar feature formed into one or more of the club head interior surfaces. In some embodiments, one or more internal club head features provided for a purpose other than securing the pneumatic insert can double as and/or form a club head retainer. For example, in some embodiments, the club head can comprise an internal mass pad that influences the club head CG position and improves ball flight performance. In such embodiments, the mass pad can form a mass pad undercut that receives an insert retainer. In some embodiments, any internal mass portion, toe mass pad, heel mass pad, shelf, weight member, internal hosel contour, or undercut can form a club head retainer. The one or more club head retainers can be integral portions of the club head body or can be separately formed and attached thereto.

In some embodiments, the cavity geometry can form one or more club head retainers. In some embodiments, as illustrated in FIG. 6, a cavity height H_C from the sole interior surface 121 to the top rail interior surface 119 decreases towards the heel 104. In such embodiments, the pneumatic insert 140 can be shaped to correspond to the cavity geometry. The pneumatic insert 140 can comprise a minimum insert height H_I proximate the insert heel end 163 that is similar to the cavity height H_C at the desired insert heel end location. This configuration prevents the pneumatic insert 140 from shifting towards the heel 104 during use. In this example, the pneumatic insert 140 shape creates an insert retainer, and the cavity geometry creates a club head retainer. Further embodiments of club head retainers are illustrated throughout the figures and are discussed in detail below.

The one or more insert retainers can be configured to engage one or more club head retainers to secure the pneumatic insert within the cavity. The one or more insert retainers can be disposed on the membrane outer surface. In some embodiments, the one or more insert retainers can be selected from the group consisting of a rib, protrusion, extension, fastener, jut, ledge, shelf, rail, and any other suitable feature extending outward from the membrane outer surface. In some embodiments, one or more insert retainers can be selected from the group consisting of a groove, channel, trench, indentation, recess, and any other similar feature formed into the membrane outer surface. In some embodiments, one or more insert retainers can be internal, such as a solid portion, weight member, magnet, or other suitable member. In such embodiments the internal insert retainer can be housed within or otherwise occupy a portion of the chamber. In such embodiments, the internal insert retainer can resist deformation or disengagement from its corresponding club head retainer.

In some embodiments, the pneumatic insert shaping creates an insert retainer. As described above, the pneumatic insert can be shaped to correspond to one or more internal club head geometries forming a club head retainer. The pneumatic insert itself can be shaped to comprise one or more protrusions, extensions, recesses, grooves, channels, or other suitable geometries for engaging a club head retainer. In some embodiments, the insert dimensions (i.e., the insert width, height, and/or depth) can create an insert retainer. For example, in some embodiments, the pneumatic insert width W_I (illustrated in FIG. 6) can be designed to correspond to the distance between two club head retainers that restrict the pneumatic insert from shifting laterally within the cavity. Specific embodiments of insert retainers are illustrated throughout the figures and are discussed in further detail below.

The pneumatic insert can be secured solely by the one or more retainers and without any additional fastening, securing, or adhesive means. In some embodiments, however, the club head can comprise an additional fastening, securing, or adhesive means to secure the pneumatic insert. In some embodiments, the pneumatic insert can be attached to one or more club head interior surfaces via an adhesive, such as an epoxy, an adhesive resin, or a polymer-based tape, such as Very High Bond (VHB™) tape. In some embodiments, the pneumatic insert can be attached to one or more club head interior surfaces via a mechanical connector or fastener.

The retainers and insert securing means described above create a substantially lightweight damping system that improves sound and feel and creates discretionary mass. The damping system can consist of the pneumatic insert and any club head features or elements that secure the pneumatic insert. For example, in some embodiments, the damping system can include the pneumatic insert and a badge, an additional coupling member (such as an adhesive, epoxy, or Very High Bond VHB™ tape), any retainer provided specifically for securing the pneumatic insert (such as a bumper, or a separate insert rib attached to the pneumatic insert), or any combination thereof. Any club head feature or retainer that either is a geometry inherent to the club head design or provides a benefit other than securing the pneumatic insert may not be considered part of the damping system. For example, a top rail undercut or lower interior undercut formed between club head interior surfaces may not be considered a part of the damping system. Similarly, a mass pad that creates a desirable CG location and also forms a club head retainer via a mass pad undercut may not be considered a part of the damping system.

The retainers and insert securing means described herein create a damping system devoid of any robust insert retaining features or components that reduce discretionary mass. The damping system comprises a damping system mass defined as the combined mass of all the constituent elements of the damping system (as described above). In some embodiments, the damping system mass can be between 1 and 20 grams. In some embodiments, the damping system mass can be less than 20 grams, less than 19 grams, less than 18 grams, less than 17 grams, less than 16 grams, less than 15 grams, less than 14 grams, less than 13 grams, less than 12 grams, less than 11 grams, less than 10 grams, less than 9 grams, less than 8 grams, less than 7 grams, less than 6 grams, less than 5 grams, less than 4 grams, less than 3 grams, or less than 2 grams.

In some embodiments, the damping system mass can be between 0.5% and 15% of the total club head mass. In some embodiments, the damping system mass can be less than 15%, less than 13%, less than 10%, less than 8%, less than 5, % less than 3%, or less than 1% of the total club head mass.

As described above, the pneumatic insert can contact and structurally reinforce portions of the club head body. In particular, the pneumatic insert can structurally reinforce the strike face, thereby allowing for control over strike face flexure. In some embodiments, the pneumatic insert allows the strike face to be thinned without sacrificing durability, thereby increasing strike face flexibility and ball speed. In some embodiments, the strike face can be thinned by approximately 0.020 to 0.030 inch in comparison to a similar club head devoid of a pneumatic insert.

Referring to FIG. 5, the club head defines a strike face thickness t_SF measured between the strike face 102 and the strike face rear surface 115. In some embodiments, the club head 100 comprising a pneumatic insert 140 comprises a strike face thickness t_SF between 0.050 and 0.250 inch. In some embodiments, the club head comprising a pneumatic insert 140 comprises a strike face thickness t_SF less than 0.250 inch, less than 0.225 inch, less than 0.200 inch, less than 0.175 inch, less than 0.150 inch, less than 0.125 inch, less than 0.100 inch, less than 0.075 inch, or less than 0.050 inch. The structural reinforcement provided by the pneumatic insert 140 reduces the strike face thickness t_SF and improves durability in comparison to a similar club head devoid of a pneumatic insert.

The insert pressure and rear surface contact area each influence how the pneumatic insert reinforces the strike face. In general, greater insert pressure and a greater rear surface contact area increase strike face reinforcement. As such, the greater the insert pressure and/or the greater the rear surface contact area, the thinner the strike face can be without sacrificing durability. Embodiments with high insert pressures (i.e., greater than 5 psi) can comprise a thinner strike face than embodiments with low insert pressures (i.e., less than 5 psi). The club head can comprise a pressure reinforcement ratio defined as the insert pressure divided by the strike face thickness t_SF. In some embodiments, the pressure reinforcement ratio is greater than 5 lb/in³. In some embodiments, the pressure reinforcement ratio is greater than 10 lb/in³, greater than 20 lb/in³, greater than 30 lb/in³, greater than 40 lb/in³, greater than 50 lb/in³, greater than 60 lb/in³, greater than 70 lb/in³, greater than 80 lb/in³, greater than 90 lb/in³, or greater than 100 lb/in³. In some embodiments, the pressure reinforcement ratio is approximately 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 lb/in³.

Further, the club head can comprise a rear surface reinforcement ratio defined as the rear surface contact area divided by the strike face thickness t_SF. In some embodiments, the rear surface reinforcement ratio is greater than 2 inch. In some embodiments, the rear surface reinforcement ratio is greater than 5, greater than 10 in inch greater than 20 inch, greater than 30 inch, greater than 40 inch, greater than 50 inch, greater than 60 inch, greater than 70 inch, greater than 80 inch, greater than 90 inch, or greater than 100 inch. In some embodiments, the rear surface reinforcement ratio is approximately 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, or 55 inch.

C. Forming of the Pneumatic Insert

The pneumatic inserts described herein can be formed by a variety of methods or processes. In some embodiments, the pneumatic insert is formed through a thermoforming process. In such embodiments, the membrane material is heated to a softening point and pressurized within a mold (or multiple molds) to achieve the desired membrane shape. In some embodiments, the thermoforming process used to form the pneumatic insert is a vacuum forming, pressure forming, mechanical forming, drape forming, matched mold forming, twin sheet forming, or billow forming method, as defined above. Typically, the membrane material is pre-heated and stretched into a thin layer or sheet. External forces are applied to the sheet, often with use of a mold (or multiple molds), to shape the layer into the desired configuration. Excess sheet material can be trimmed from around the desired insert shape.

In other embodiments, the pneumatic insert can be formed by a process other than thermoforming. In some embodiments, the pneumatic insert can be plastic molded, injection molded, or molded by any other suitable process. In some embodiments, the membrane can be formed as a two-part membrane. In such embodiments, the membrane can be molded or otherwise formed as a first membrane portion and a second membrane portion, wherein the first and second membrane portions are coupled together prior to inflation. A two-part membrane allows for more complex insert shapes.

The pneumatic insert can be installed into the cavity in a fully inflated state, a partially inflated state, or a fully deflated state. In embodiments wherein the pneumatic insert is installed in the fully-inflated state, the pneumatic insert is pressurized to the desired insert pressure prior to installation in the cavity. In such embodiments, the club head can comprise a rear opening sized to allow the fully inflated insert to be inserted into the cavity. In some such embodiments, the pneumatic insert can be devoid of a valve, because the insert does not need to be inflated after installation. In some embodiments, the pneumatic insert can be formed with a sacrificial valve. In such embodiments, the pneumatic insert can be inflated through the sacrificial valve. After inflation, the sacrificial valve can be trimmed away, and the valve opening can be sealed, thereby creating a fully inflated, valveless pneumatic insert. In some embodiments, the valve opening is heat sealed.

In some embodiments wherein the pneumatic insert is installed in the partially inflated state or fully inflated, the pneumatic insert can comprise a valve. In such embodiments, the pneumatic insert can be inflated via the valve after installation. The pneumatic insert can thereby be inflated in the cavity, from the partially inflated or fully deflated state to full inflation at the desired insert pressure. In some embodiments, inflating the pneumatic insert within the cavity allows for a greater pressure or a larger insert than might otherwise be possible if the pneumatic insert is inflated prior to installation.

II. Embodiments of Club Heads Comprising a Pneumatic Insert

FIGS. 11-58 illustrate various embodiments of club heads comprising one or more pneumatic inserts. The following embodiments illustrate and describe pneumatic inserts as applied to cavity-back, fully enclosed hollow-body, and capped-hollow body club heads. Any specific embodiments of pneumatic inserts, retainers, or other club head features can be applied to or used in combination with any club head type and are not limited to the specific club head type in which they are illustrated. Similarly, any club head type (i.e., cavity-back, fully enclosed hollow-body, or capped-hollow body) can comprise any one or combination of the features described herein.

D. Cavity-Back Club Head with Pneumatic Insert

FIGS. 9-12 illustrate a cavity-back club head 200 comprising a pneumatic insert 240. As described above, the cavity-back club head 200 comprises a rear opening 222 that communicates an open cavity 225 with the club head exterior.

Referring to FIGS. 11 and 12, the club head 200 comprises a pneumatic insert 240 at least partially filling the open cavity 225. The pneumatic insert 240 can comprise similar characteristics or properties to any of the other pneumatic insert embodiments described herein. In some embodiments, the pneumatic insert 240 can be inserted into the open cavity 225 through the rear opening 222. In the embodiment illustrated in FIGS. 6 and 7, the rear opening 222 is left uncovered after the pneumatic insert 240 is installed, and a portion of the pneumatic insert 240 is exposed to the club head exterior. Referring to FIG. 12, the insert forward surface 246 can abut the strike face rear surface 215, and a portion of the insert rear surface 248 can be exposed to the club head exterior through the rear opening 222.

The club head body geometry forms a plurality of club head retainers configured to secure the pneumatic insert 240. Referring to FIGS. 10 and 12, the plurality of club head retainers includes a top rail undercut 230. The club head 200 forms a top rail perimeter portion 228 extending soleward from a rear end 211 of the top rail 210. The top rail undercut 230 is formed between interior surfaces of the top rail perimeter portion 228, the top rail 210, and the strike face 202. The top rail undercut 230 is configured to receive one or more insert retainers, described in further detail below. The plurality of club head retainers further includes a lower interior undercut 231. The club head 200 can form a mass pad 280 located in a low and rearward portion of the open cavity 225, proximate both the sole 212 and the rear wall 216. The mass pad 280 comprises a mass pad forward surface 281 disposed toward the strike face 202 but spaced rearward from the strike face rear surface 215. The lower interior undercut 231 is formed between the strike face rear surface 215 and the mass pad forward surface 281. The lower interior undercut 231 is configured to receive one or more insert retainers, described in further detail below.

In some embodiments, as illustrated in FIG. 3, the plurality of club head retainers can further comprise a strut 235 spanning across at least a portion of the rear opening 222. When the pneumatic insert 240 is fully installed, the strut 235 acts as a stop against the insert rear surface 248, thereby preventing the pneumatic insert 240 from exiting through the rear opening 222 during use. In the illustrated embodiment, the strut 235 extends between the top rail 210 and the rear wall 216. In some embodiments, the strut 235 can extend diagonally across the rear opening 222. In the illustrated embodiment, the strut 235 is angled such that the strut top end 236 is located heelward of the strut bottom end 237. In other embodiments, the strut 235 can be provided in any suitable orientation. In some embodiments, rather than extending between the top rail 210 and the rear wall 216, the strut 235 can extend between the top rail 210 and the toe 206 or between the top rail 210 and the heel 204. In some embodiments, the strut can extend between any combination of the top rail 210, the heel 204, the toe 206, and the rear wall 216. In some embodiments, the strut can extend in a substantially vertical direction (i.e., between the top rail 210 and the sole 206), in a substantially horizontal direction (i.e., between the heel 204 and the toc 206), or in a substantially diagonal or angled direction.

In addition to securing the pneumatic insert 240, the strut 235 can damp vibrations within portions of the club head body 201. The strut 235 can structurally reinforce and damp thin portions of the top rail 210 and/or the rear wall 216 that typically exhibit high frequency vibrations. Further, in some embodiments, the strut 235 can act as a perimeter weight that increases MOI and/or provides a more rearward CG position. In some embodiments, the strut 235 can be integrally cast as part of the club head body 201. In other embodiments, the strut 235 can be separately formed and subsequently attached to the club head body 201. In such embodiments, the strut 235 can be coupled to the body 201 via any suitable mechanical, chemical, or adhesive means, such as welding, brazing, swedging, or adhering via epoxy, or co-molding. In some embodiments, the club head 200 can comprise multiple struts. The club head can comprise one, two, three, four, five, six, seven, eight, nine, ten, or any suitable number of struts. In some embodiments, such as the embodiment shown in FIG. 11, the club head 200 may be devoid of a strut.

The rear opening 222 can be sized to function as a club head retainer. The rear opening 222 can be substantially small to prevent the larger pneumatic insert 240 from exiting through the open cavity 225 during use. Further, in some embodiments, the rear opening area can be reduced to allow the pneumatic insert 240 to be secured by a lightweight badge, thereby creating discretionary mass over the robust insert retaining features of many prior art club heads. In some embodiments, the rear opening 222 can comprise a rear opening area between 1.0 and 2.5 in². In some embodiments, the rear opening area can be less than 2.5 in², less than 2.25 in², less than 2.0 in², less than 1.75 in², less than 1.50 in², less than 1.25 in², or less than 1.0 in².

The pneumatic insert 240 comprises a plurality of insert retainers configured to engage the plurality of club head retainers and secure the pneumatic insert 240 within the open cavity 225. As illustrated in FIG. 12, the insert top end 261 is configured to extend into the top rail undercut 230 and abuts one or more of the top rail perimeter portion 228, the top rail 210, and the strike face rear surface 215. The insert top end 261 engages the top rail perimeter portion 228, preventing the pneumatic insert 240 from exiting through the rear opening 222 during use. Further, the insert bottom end 262 is configured to extend into the lower interior undercut 231 and abuts one or more of the mass pad forward surface 281, the sole 212, and the strike face rear surface 215. The insert bottom end 262 engages the mass pad forward surface 281, preventing the pneumatic insert 240 from exiting through the rear opening 222 during use.

Further, the insert height H_I functions as an insert retainer. Because the insert height H_I is greater than the rear opening height H_O, the rear wall 216 prevents the pneumatic insert 240 from exiting through the rear opening 222 during use. In some embodiments, the insert height H_I can be substantially greater than the rear opening height H_O. In some embodiments, a ratio H_I/H_O between the insert height H_I and the rear opening height H_O can be between 1.25 and 3.0. In some embodiments, the H_I/H_O ratio can be between 1.25 and 1.5, between 1.5 and 1.75, between 1.75 and 2.0, between 2.0 and 2.25, between 2.25 and 2.5, between 2.5 or 2.75, or between 2.75 and 3.0. In some embodiments, the H_I/H_O ratio can be greater than 1.25, greater than 1.5, greater than 1.75, greater than 2.0, greater than 2.25, greater than 2.5, greater than 2.75, or greater than 3.0. The greater the H_I/H_O ratio, the more secure the pneumatic insert 240 is within the open cavity 225.

In some embodiments, the pneumatic insert 240 can be installed at an angle to allow passage through the smaller rear opening 222. In such embodiments, the pneumatic insert position can then be manipulated to engage the insert retainers with the club head retainers and secure the pneumatic insert 240. In other embodiments, the pneumatic insert 240 can be inserted into the open cavity 225 in a deflated or partially inflated state fit through the small rear opening 222. In such embodiments, the pneumatic insert 240 can be fully inflated within the open cavity 225, such that the pneumatic insert 240 cannot be removed from the open cavity 225 without first being deflated. In some embodiments, alignment of the uninflated pneumatic is achievable using one or more insert retainers configured to engage one or more club head retainers.

In some embodiments, the pneumatic insert 240 is secured within the open cavity 225 solely by the retainers and without any additional fastening, securing, or adhesive means. In other embodiments, an additional coupling means can further secure the pneumatic insert 240. In some embodiments, an adhesive member can couple the pneumatic insert 240 to the club head body 201. In some embodiments, the adhesive member can couple the insert forward surface 246 to the strike face rear surface 215. In some embodiments, the adhesive member can be a polymer-based tape, such as Very High Bond (VHB™) tape. In other embodiments, the adhesive member can be any other suitable tape or adhesive means capable of securing the pneumatic insert 240 within the open cavity 225.

The pneumatic insert 240 can occupy all or a portion of the open cavity 225. The pneumatic insert 240 can comprise any position or orientation similar to those described herein. In some embodiments, the pneumatic insert 240 can comprise an insert contact area, a back surface contact area, and/or a scoring area back surface contact area within the ranges disclosed above. In some embodiments, as illustrated in FIG. 3, the pneumatic insert 240 can occupy only a central portion of the open cavity 225 and/or be located primarily behind the scoring area. As described above, configuring the pneumatic insert to occupy only a central portion of the open cavity 225 can improve damping while reducing the insert mass.

The cavity-back design of the club head 200 provides a substantially lightweight damping system. The club head 200 requires no badge or covering to conceal the pneumatic insert 240 within the open cavity 225. Therefore, the damping system of club head 200 consists only of the pneumatic insert 240 and any additional adhesive members or coupling means (i.e., any adhesives, epoxies, or tapes). As such, in some embodiments, club head 200 comprises a damping system mass less than 8 grams, less than 7 grams, less than 6 grams, less than 5 grams, less than 4 grams, less than 3 grams, or less than 2 grams. In some embodiments, club head 200 comprises a damping system mass less than 3%, less than 2.5%, less than 2.0%, less than 1.5%, less than 1.0%, or less than 0.5% of the overall club head mass.

E. Capped Hollow-Body Club Head with Pneumatic Insert

FIGS. 14-18 illustrate a capped hollow-body club head 300 comprising a pneumatic insert 340. The club head 300 comprises a rear wall 316 forming a rear opening 322. The badge 350 covers the rear opening 322 to enclose a hollow interior cavity 325. The badge 350 comprises a badge interior surface 352 interfacing the enclosed interior cavity 325 and a badge exterior surface 354 exposed to the exterior of the club head 300.

In some embodiments, the club head body 301 can be substantially similar to the club head body 201 described above.

Referring to FIGS. 15 and 16, the rear wall 316 and the top rail 310 combine to form a lap joint 324 circumscribing the rear opening 322. The lap joint 324 extends into the rear opening 322 from the top rail 310 and the rear wall 316 and provides an adhesion surface configured to receive the badge 350. The lap joint 324 can be recessed from the exterior surface of the rear wall 316 such that the badge exterior surface 356 is flush or substantially flush with the rear wall 316. The lap joint 324 can be continuous or non-continuous around the rear opening 322. The lap joint 324 can comprise a lap joint width WL measured from the edge of the rear wall 316 or the top rail 310 to the rear opening 322. In some embodiments, the lap joint width WL can range from approximately 0.030 inch to 0.250 inch. In some embodiments, the lap joint width WL can be between 0.030 and 0.050 inch, between 0.050 and 0.100 inch, between 0.100 and 0.150 inch, between 0.150 inch and 0.200 inch, or between 0.200 and 0.250 inch. In some embodiments, the lap joint width WL can be approximately constant around the rear opening 322. In other embodiments, the lap joint width WL vary.

In most embodiments, the badge 350 is secured to the club head 300 through adhesion via epoxy or another adhesive material. In other embodiments, the badge 350 can be secured to the club head 300 using mechanical fastening means such as screws, snap hooks, press fitting, or any means for binding. In some embodiments, the badge 350 can be secured using a combination of both an adhesive and mechanical fastening means. The badge 350 can be formed from a polymer or flexible material with a low shore durometer (i.e., soft material). The pneumatic insert can be formed from a polymer matrix. The polymeric matrix can comprise glass-filled elastomer, a stainless steel-filled elastomer, a tungsten-filled elastomer, a thermoplastic polyurethane (TPU) composite, a thermoplastic elastomer (TPE) composite, or any other elastomer matrix composite, a Kevlar® (aramid) fiber-reinforced polymer, a carbon-fiber reinforced polymer, rubber, ethylene-vinyl acetate foam, polymer-based foam, any combination of a suitable resin and a suitable reinforcing fiber, or any combination of the above materials. Soft or flexible materials improve the feel and sound of the club head 300 through impact.

Referring to FIGS. 15, 17, and 18, the club head 300 comprises a pneumatic insert 340 at least partially filling the hollow interior cavity 325. The pneumatic insert 340 can comprise similar characteristics or properties to the pneumatic inserts described above, or any of the other pneumatic insert embodiments described herein. In some embodiments, the pneumatic insert 340 can be installed into the interior cavity 325 through the rear opening 322 and subsequently covered with the badge 350. The badge 350 thereby conceals and secures the pneumatic insert 340 within the hollow interior cavity 325.

FIGS. 15 and 17 illustrate the pneumatic insert 340 comprising a valve 355 configured for pneumatic insert inflation. The valve 355 protrudes through an opening in the membrane 342 and into the chamber 344. In some embodiments, the valve 355 is located on the insert rear surface 348 and above, the rear wall 316, allowing the valve 355 to be accessible through the rear opening 322 before the badge 350 is installed. The valve 355 includes an inlet 356 located along the membrane outer surface 347 and a nozzle 357 extending into the chamber 344. In some embodiments, the inlet 356 can abut the badge interior surface 352 after installation. Although FIGS. 14-18 illustrate the pneumatic insert 340 comprising a valve 355, the capped hollow-body club head 300 can comprise a pneumatic insert devoid of a valve.

The club head body geometry forms a plurality of club head retainers configured to secure the pneumatic insert 240. Similar to club head 200, club head 300 comprises a first club head retainer in the form of a top rail undercut 330 formed between interior surfaces of a top rail perimeter portion 328, the top rail 310, and the strike face 302. The club head 300 forms a mass pad 380 similar to mass pad 280 and a second club head retainer in the form of a lower interior undercut 381 between the strike face rear surface 315 and the mass pad forward surface 381.

In some embodiments, the plurality of club head retainers can comprise a strut 335 similar to strut 235 illustrated in FIG. 3. In some embodiments, the badge 350 can be shaped complementarily to the shape of the strut 335. In some embodiments comprising a strut 335, the badge 350 can comprise a channel recessed into the badge interior surface 352. The channel can correspond to the size, shape, and location of the strut 335. The badge 350 covers the strut 335 such that the strut 335 fits within the channel portion and is visibly obscured from the rear exterior of the club head 300. In some embodiments, such as the embodiment shown in FIG. 11, the club head 200 may be devoid of a strut. In such embodiments, the badge 350 may be devoid of a channel recessed into the badge interior surface 352.

Similar to rear opening 222, the rear opening 322 can function as a club head retainer. The rear opening 322 can be substantially small to prevent the larger pneumatic insert 340 from exiting through the hollow interior cavity 325 during use. The rear opening 322 can comprise a similar size and/or dimensions to rear opening 222.

Further, the badge 350 can be a club head retainer. As described above, the badge 350 covers the rear opening 322 and secures the pneumatic insert 340 within the hollow interior cavity 325.

The pneumatic insert 340 comprises a plurality of insert retainers configured to engage the plurality of club head retainers and secure the pneumatic insert 340 within the hollow interior cavity 325. Similar to pneumatic insert 240, the pneumatic insert 340 comprises a first insert retainer at the insert top end 361 that engages the top rail undercut 330. The pneumatic insert 340 further comprises a second insert retainer at the insert bottom end 362 that engages the lower interior undercut 331.

Similar to pneumatic insert 240, insert height H_I functions as an insert retainer, because the insert height H_I is greater than the rear opening height H_O. The club head 300 can comprise a H_I/H_O ratio within the ranges described above in relation to club head 200.

In some embodiments, the pneumatic insert 340 can be installed at an angle to allow passage through the smaller rear opening 322. In such embodiments, the pneumatic insert position can then be manipulated to engage the insert retainers with the club head retainers and secure the pneumatic insert 340. In other embodiments, the pneumatic insert 340 can be inserted into the hollow interior cavity 325 in a deflated or partially inflated state fit through the small rear opening 322 (i.e., a rear opening 322 comprising a small rear opening area, as described above). In such embodiments, the pneumatic insert 340 can be fully inflated within the hollow interior cavity 325, such that the pneumatic insert 340 cannot be removed from the open cavity 325 without first being deflated.

In some embodiments, the pneumatic insert 340 is secured within the hollow interior cavity 325 solely by the retainers and without any additional fastening, securing, or adhesive means. In other embodiments, an additional coupling means can further secure the pneumatic insert. In some embodiments, an adhesive member can couple the pneumatic insert 340 to the club head body 301. In some embodiments, the adhesive member can couple the insert forward surface 346 to the strike face rear surface 315. In some embodiments, the adhesive member can be a polymer-based tape, such as Very High Bond (VHB™) tape. In other embodiments, the adhesive member can be any other suitable tape or adhesive means capable of securing the pneumatic insert 340 within the hollow interior cavity 325.

The pneumatic insert 340 can occupy all or a portion of the hollow interior cavity 325. The pneumatic insert 340 can comprise any position or orientation similar to those described herein. In some embodiments, the pneumatic insert 340 can comprise an insert contact area, a back surface contact area, and/or a scoring area back surface contact area within the ranges disclosed above. In some embodiments, as illustrated in FIGS. 15 and 18, the pneumatic insert 340 can occupy only a central portion of the hollow interior cavity 325 and/or be located primarily behind the scoring area. As described above, configuring the pneumatic insert to occupy only a central portion of the hollow interior cavity 325 can improve damping while reducing the insert mass.

The capped hollow-body design of the club head 300 provides a substantially lightweight damping system. As described above, the rear opening 322 is substantially small and therefore requires only a small badge 350 covering said rear opening 322 and secure the pneumatic insert 340 within the hollow interior cavity 325. Therefore, the damping system consists of the pneumatic insert 340, the badge 350, and any additional adhesive members or coupling means. As such, in some embodiments, club head 300 comprises a damping system mass less than 15 grams, less than 14 grams, less than 13 grams, less than 12 grams, less than 11 grams, less than 10 grams, less than 9 grams, less than 8 grams, less than 7 grams, less than 6 grams, less than 5 grams, less than 4 grams, less than 3 grams, or less than 2 grams. In some embodiments, club head 300 comprises a damping system mass less than 5%, less than 4%, less than 3%, less than 2% or less than 1% of the overall club head mass.

FIGS. 19-22 illustrate another embodiment of a capped hollow-body club head 400 comprising a pneumatic insert 440. The club head 400 can be substantially similar to club head 300 described above, but for differences in the badge 450 and shape of the pneumatic insert 440.

Referring to FIG. 19, the badge 450 can cover a significant portion of the rear end 411. In the illustrated embodiment, the badge 450 can extend substantially from the top rail 410 to the sole 412. Although the badge 450 covers a rear opening 422, its size gives the club head 400 the appearance of a fully enclosed hollow-body club head, which may be preferable to some players.

Referring to FIG. 20, the rear opening 422 can still be substantially small and can make up only a small portion of the club head rear end 411. In some embodiments, the rear opening area is substantially similar to the rear opening areas described above in relation to rear opening 222 and rear opening 322. The badge 450 can be significantly larger than the rear opening 422 to reduce the rear opening area while also creating the appearance of a fully-enclosed hollow body club head. The lap joint 424 can comprise a lower lap surface 429 configured to receive a large portion of the badge 450. The lower lap surface 429 forms a lower portion of the lap joint 424 and extends from a bottom edge of the rear opening 422 to near the sole 412. The lower lap surface 429 thereby covers a majority of the rear wall 416. In some embodiments, the lower lap surface 429 comprises a lower lap surface area between 1.0 and 5.0 in². In some embodiments, the lower lap surface area can be greater than 1.0 in², greater than 2.0 in², greater than 3.0 in², greater than 4.0 in², or greater than 5.0 in².

Referring to FIG. 22, the pneumatic insert 440 is shaped to facilitate easy installation. The pneumatic insert 440 can comprise a trimmed corner edge 498 that follows the shape of the strut 435. The trimmed corner edge 498 can connect the insert top end 461 to the insert toe end 464. The trimmed corner edge 498 allows the pneumatic insert 440 to be installed underneath the strut 435 without the corner of the pneumatic insert 440 interfering with or getting stuck against the strut 435. In the illustrated embodiment, the pneumatic insert 440 is located substantially behind the scoring area. In other embodiments, the pneumatic inserts 440 occupies a greater portion of the cavity and extends beyond the scoring area.

The club head 400 comprises a plurality of retainers, similar to the retainers of club heads 200 and 300. Referring to FIG. 21, the insert top end 461 engages a top rail undercut 430 and the insert bottom end 462 engages a lower interior undercut 431 formed between the strike face rear surface 415 and the mass pad forward surface 481. Similar to pneumatic inserts 240, 340, the insert height H_I functions as an insert retainer, because the insert height H_I is greater than the rear opening height H_O. The club head 400 can comprise a H_I/H_O ratio within the ranges described above in relation to club heads 200, 300. The badge 450 and the strut 435 function as club head retainers, similar to those described above in relation to club heads 200, 300.

FIG. 65 illustrates an alternative insert shape that facilitates easy installation. The insert 4240 comprises a heel-side corner edge 4296 and a toe-side corner edge 4298 that are angled towards each other and converge at an apex 4299. The toe-side corner edge 4298 can extend diagonally from the insert toe end 4264 to the apex 4299. The heel-side corner edge 4296 can extend diagonally from the insert heel end 4263 to the apex. The toc-side corner edge 4298 can generally follow the shape of the strut 4235. The toe-side corner edge 4298 allows the pneumatic insert 4240 to be installed underneath the strut 4235 without the corner of the pneumatic insert 4240 interfering with or getting stuck against the strut 4235. The heel-side corner edge 4296 can generally follow the shape of the top rail 4210 or the shape of the rear opening 4222. The heel-side corner edge 4296 allows the pneumatic insert 4240 to be installed through the rear opening 4222 without the corner of the pneumatic insert 4240 interfering with or getting stuck against the rear opening edge. In the illustrated embodiment, the pneumatic insert 4240 is located substantially behind the scoring area. In other embodiments, the pneumatic insert 4240 occupies a greater portion of the cavity and extends beyond the scoring area. In some embodiments, as illustrated in FIGS. 65 and 66, the pneumatic insert 4240 may comprise a smaller size (relative to other pneumatic inserts shown or described herein) that allows it to more easily be inserted into the rear opening 4222.

In some embodiments, the pneumatic insert 4240 can be configured such that the pneumatic insert rear surface 4248 is spaced from the strut 4235. In other embodiments, the pneumatic insert rear surface 4248 does not contact any club head interior surface apart from the strike face rear surface 4215 and/or the sole interior surface 4221. As such, a front-to-back thickness of the pneumatic insert 4240, measured between the pneumatic insert forward surface 4246 and the pneumatic insert rear surface 4248, can vary to create space between the pneumatic insert 4240 and the strut 4235 or other interior surfaces upon installation. As illustrated in FIG. 66, an upper portion of the pneumatic insert 4240 comprises a tapered, thin region to create separation between the pneumatic insert 4240 and the strut 4235. Allowing space between the pneumatic insert 4240 and the strut 4235 and/or other rearward interior club head surfaces allows the badge 4250 to be installed without restriction from the pneumatic insert 4240.

The club head 4200 comprises a plurality of retainers, similar to the retainers of club heads 200, 300, and 400. Referring to FIG. 66, the insert bottom end 4262 engages a lower interior undercut 4231 formed between the strike face rear surface 4215 and the mass pad forward surface 4281. In some embodiments, the pneumatic insert 4240 comprises a smaller size and does not engage the top rail undercut 4230. Similar to pneumatic inserts 240, 340, 440 the insert height H_I functions as an insert retainer, because the insert height H_I is greater than the rear opening height H_O. The club head 4240 can comprise a H_I/H_O ratio within the ranges described above in relation to club heads 200, 300, 400. The badge 4250 and the strut 4235 function as club head retainers, similar to those described above in relation to club heads 200, 300, 400.

In some embodiments, the pneumatic insert 440 can be installed at an angle to allow passage through the rear opening 422. In such embodiments, the pneumatic insert position can then be manipulated to engage the insert retainers with the club head retainers and secure the pneumatic insert 440. In other embodiments, the pneumatic insert 440 can be inserted into the hollow interior cavity 425 in a deflated or partially inflated state fit through the rear opening 422. In such embodiments, the pneumatic insert 440 can be fully inflated within the hollow interior cavity 425, such that the pneumatic insert 440 cannot be removed from the open cavity 425 without first being deflated. In some embodiments, alignment of the uninflated pneumatic insert 440 is achievable using one or more insert retainers configured to engage one or more club head retainers.

In some embodiments, the pneumatic insert 440 is secured within the hollow interior cavity 425 solely by the retainers and without any additional fastening, securing, or adhesive means. In other embodiments, an additional coupling means can further secure the pneumatic insert. In some embodiments, an adhesive member can couple the pneumatic insert 340 to the club head body 401. In some embodiments, the adhesive member can couple the insert forward surface 446 to the strike face rear surface 415. In some embodiments, the adhesive member can be a polymer-based tape, such as Very High Bond (VHB™) tape. In other embodiments, the adhesive member can be any other suitable tape or adhesive means capable of securing the pneumatic insert 340 within the hollow interior cavity 425.

F. Fully Enclosed Hollow-Body Golf Club Head with Pneumatic Insert

FIGS. 23-25 illustrate a fully-enclosed hollow-body club head 500 comprising a pneumatic insert 540. The club head 500 comprises a rear wall 516 extending continuously from the sole 512 to the top rail 510. The strike face 502, the top rail 510, the heel 504, the toe 506, the sole 512, and the rear wall 516 enclose a hollow interior cavity 525. In some embodiments, the club head 500 comprises a port 518 providing access to the hollow interior cavity 525. As illustrated in FIG. 23, the port 518 can be located in the toe 506, proximate the sole 512. In other embodiments, the port 518 can be provided on another portion of the club head body 501, such as the sole 512, the rear wall 516, the heel 504, the top rail 510, or any combination thereof. In some embodiments, the port 518 is further configured to receive a weight member. The weight member can fill the port 518 and seal the hollow interior cavity 525. The weight member can be inserted into the port 518 after the pneumatic insert 540 is installed, enclosing the pneumatic insert 540 within the hollow interior cavity 525. In some embodiments, the port 518 can be threaded to receive a complementarily threaded screw weight.

Referring to FIGS. 24 and 25, the club head 500 comprises a pneumatic insert 540 at least partially occupying the hollow interior cavity 525. The pneumatic insert 540 can comprise similar characteristics or properties to any of the pneumatic insert embodiments described herein.

The club head 500 comprises a plurality of retainers that secure the pneumatic insert 540 within the interior cavity 525. Referring to FIG. 24, the strike face rear surface 515, the top rail 510, and the rear wall 516 combine to form a top rail undercut 530. The insert top end 561 forms an insert retainer that engages the top rail undercut 530. Further, the club head body 501 comprises a mass pad 580 that forms a lower interior undercut 531. Specifically, the mass pad 580 comprises a mass pad forward surface 581 that angles toward the strike face 502. The lower interior undercut 531 is formed as the space between the mass pad forward surface 581 and the sole interior surface 521. In some embodiments, as illustrated in FIG. 24, the pneumatic insert 540 comprises a lower rear protrusion 538 that forms an insert retainer and extends away from the insert forward surface 546 proximate the insert bottom end 562. The lower rear protrusion 538 engages the lower interior undercut 531 and secures the pneumatic insert 540. In some embodiments, the lower rear protrusion 538 occupies the entire lower interior undercut 531. In some embodiments, the lower rear protrusion 538 can interlock with a portion of the mass pad 580.

Further, the pneumatic insert 540 can comprise an upper rear protrusion 539 that forms an insert retainer and extends away from the insert forward surface 546. The upper rear protrusion 539 can be located above the lower rear protrusion 538. The upper rear protrusion 539 can engage a mass pad top surface 582, thereby further securing the pneumatic insert 540.

The pneumatic insert 540 can occupy all or a portion of the interior cavity 525. The pneumatic insert 540 can comprise any position or orientation similar to those described herein. In some embodiments, the pneumatic insert 540 can comprise an insert contact area, a back surface contact area, and/or a scoring area back surface contact area within the ranges disclosed above. In some embodiments, as illustrated in FIG. 25, the pneumatic insert 540 can occupy only a central portion of the interior cavity 525 and/or be located primarily behind the scoring area. As described above, configuring the pneumatic insert to occupy only a central portion of the interior cavity 525 can improve damping while reducing the insert mass.

In some embodiments, the pneumatic insert 540 is secured within the interior cavity 525 solely by the retainers and without any additional fastening, securing, or adhesive means. In other embodiments, an additional coupling means can further secure the pneumatic insert. In some embodiments, an adhesive member can couple the pneumatic insert 540 to the club head body 501. In some embodiments, the adhesive member can couple the insert forward surface 546 to the strike face rear surface 515. In some embodiments, the adhesive member can be a polymer-based tape, such as Very High Bond (VHB™) tape. In other embodiments, the adhesive member can be any other suitable tape or adhesive means capable of securing the pneumatic insert 540 within the interior cavity 525.

In some embodiments, the pneumatic insert 540 can be inserted into the hollow interior cavity 525 through the port 518. In some embodiments, the pneumatic insert 540 can be inserted into the hollow interior cavity 525 in a fully deflated state. The pneumatic insert 540 can then be inflated to an expanded state wherein the pneumatic insert 540 occupies a portion of the hollow interior cavity 525. Referring now to FIG. 26, the pneumatic insert 540 can be inserted into the hollow interior cavity 525 by an installation assembly 5000. The installation assembly 5000 comprises a locating tube 5010 and an inflation tube 5020. The locating tube 5010 can be sized to fit within the port 518 and guide the installation of the pneumatic insert 540. The locating tube 5010 comprises an outer diameter OD and an inner diameter ID defining a locating tube bore 5015. The outer diameter OD of the locating tube 5010 can generally correspond to the diameter of the port 518. In some embodiments, the locating tube 5010 can be threaded to correspond to a threaded port 518, ensuring the locating tube 5010 is properly aligned within the port 518. The locating tube 5010 allows the pneumatic insert 540 to be inserted through the locating tube bore 5015 and into the hollow interior cavity 525 via the port 518. In some embodiments, the membrane 542 can be fully deflated and tightly rolled to fit through the locating tube bore.

The inflation tube 5020 can be attached to the deflated pneumatic insert 540. The inflation tube 5020 can be an elongated tubular member capable of interfacing with an air pump or other inflation device. A valve 5025 is coupled to an end of the inflation tube 5020 opposite the end connected to the pneumatic insert 540. The valve 5025 selectively permits fluid communication between the inflation device and the inflation tube 5020, thereby allowing the pneumatic insert 540 to be filled. Once the pneumatic insert 540 is inserted into the hollow interior cavity 525, the inflation tube 5020 can protrude out of the hollow interior cavity 525 through the port 518 such that the valve 5025 is accessible from the club head exterior. The pneumatic insert 540 can then be inflated through the inflation tube 5020. Following inflation, the inflation tube 5020 can be clamped near the end connected to the pneumatic insert 540. The clamped end can be sealed and the locating tube 5010 and the remainder of the inflation tube 5020 can be removed from the port 518. In some embodiments, the clamped end of the locating tube 5010 can be heat sealed.

G. Club Head with Bumpers

In the illustrated embodiments above, the interior cavity geometry (i.e., interior undercuts or mass pad geometries) forms one or more club head retainers that secure the pneumatic insert within the interior cavity. As discussed above, the interior cavity geometry can retain the pneumatic insert such that no coupling mechanisms or adhesives are needed. In some embodiments, the club head comprises one or more bumpers forming a club head retainer. The bumpers can secure the pneumatic insert in the intended position during use. In some embodiments, the bumpers complement the retaining effects of the interior undercut or mass pad geometries. In other embodiments, the bumpers can retain the pneumatic insert without the help of any undercut or mass pad geometries. The bumpers can allow for more precise placement of the pneumatic insert during installation and prevent the pneumatic insert from moving within the interior cavity during use.

In some embodiments, the club head body can integrally form one or more bumpers. In such embodiments, the bumpers can project into the interior cavity from one or more of the club head interior surfaces. In many other embodiments, one or more bumpers can be separately formed from the club head body and attached thereto. In some embodiments, the bumpers can be substantially small (described in further detail below). Small bumpers retain the pneumatic insert in the desired position without using significant amounts of discretionary mass. Any one or combination of the bumpers described below can be combined with any embodiment of the golf club head comprising a pneumatic insert described herein.

FIGS. 27-29 illustrate a first embodiment of a club head comprising bumpers. The club head 600 comprises a pair of top rail bumpers, including a heel-side top rail bumper 672a and a toe-side top rail bumper 672b. The top rail bumpers 672a, 672b project into the interior cavity 625 from the top rail interior surface 619. As illustrated in FIGS. 27 and 28, the top rail bumpers 672a, 672b can curve along the transition between the strike face rear surface 615, the top rail interior surface 619, and the rear wall interior surface 623. In some embodiments, the top rail bumpers 672a, 672b can be located solely on the strike face rear surface 615, solely on the top rail interior surface 619, solely on the rear wall interior surface 623, or on any combination of said surfaces.

In some embodiments, the top rail bumpers 672a, 672b are spaced apart by a distance similar to or slightly larger than the pneumatic insert width W_I. As such, the top rail bumpers 672a, 672b bound the pneumatic insert 640 on both its heel side and its toe side, near the top rail 610. The top rail bumpers 672a, 672b prevent the pneumatic insert 640 from moving laterally within the interior cavity 625. The insert width W_I thereby creates an insert retainer that engages the bumpers 672a, 672b.

The top rail bumpers 672a, 672b precisely place the pneumatic insert 640 at a desired location. The top rail bumpers 672a, 672b can be used as alignment aids to locate the pneumatic insert 640 in the proper heel-to-toe position. In some embodiments, the top rail bumpers 672a, 672b can be located just outside, but adjacent to, the scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. This configuration locates the pneumatic insert 640 directly behind the scoring area. For example, in some embodiments, the heel-side top rail bumper 672a can contact the strike face rear surface 615 at a location slightly heelward of the area heel-side boundary plane 1020, whereas the toe-side top rail bumpers 672b can contact the strike face rear surface 615 at a location slightly toeward of the toe-side boundary plane 1025. Although FIGS. 27-30 illustrate two top rail bumpers, other embodiments can include one, two, three, four, five, six, or any other suitable number of top rail bumpers.

The top rail bumpers 672a, 672b can be substantially small, thereby retaining the pneumatic insert 640 in the proper position without using a large amount of discretionary mass. Referring to FIG. 27, the top rail bumpers 672a, 672b comprise a thickness t_TB measured between opposing surfaces of a given top rail bumper. In some embodiments, the thickness t_TB can be between 0.010 and 0.100 inch. In some embodiments, the thickness t_TB can be less than 0.100 inch, less than 0.090 inch, less than 0.080 inch, less than 0.070 inch, less than 0.060 inch, less than 0.050 inch, less than 0.040 inch, less than 0.030 inch, less than 0.020 inch, or less than 0.010 inch. The top rail bumpers 672a, 672b are substantially thin, such that they retain the pneumatic insert 640 at the intended position without contributing a significant amount of mass.

In some embodiments the thicknesses t_TB of the heel-side top rail bumper 672a and the toc-side top rail bumper 672b are substantially the same. In some embodiments, the thickness t_TB of the heel-side top rail bumper 672a can differ from that of the toe-side top rail bumper 672b. In some embodiments, the thickness t_TB can be substantially constant throughout a given top rail bumper, whereas in other embodiments, the thickness t_TB can vary along different portions of a given top rail bumper.

Referring to FIG. 29, the top rail bumpers 672a, 672b comprise a height H_TB measured perpendicular to the interior surfaces from which the top rail bumpers 672a, 672b extend. In some embodiments, the height H_TB can be between 0.050 and 0.500 inch. In some embodiments, the height H_TB can be less than 0.500 inch, less than 0.400 inch, less than 0.300 inch, less than 0.200 inch, less than 0.100 inch, or less than 0.050. The top rail bumpers 672a, 672b are sufficiently tall to retain the pneumatic insert 640 in its intended position, without being unnecessarily tall and introducing extra mass.

In some embodiments the height H_TB of the heel-side top rail bumper 672a and the toc-side top rail bumper 672b are substantially the same. In some embodiments, the height H_TB of the heel-side top rail bumper 672a can differ from that of the toe-side top rail bumper 672b. In some embodiments, the height H_TB can be substantially constant throughout a given top rail bumper, whereas in other embodiments, the height H_TB can vary along different portions of a given top rail bumper. For example, one or more of the top rail bumpers 672a, 672b can have a greater height proximate the rear wall interior surface 623 than proximate the strike face rear surface 615. In such embodiments, the top rail bumpers 672a, 672b can retain the pneumatic insert 640 in its intended position without hindering strike face 602 flexure.

FIGS. 30 and 31 illustrate a second embodiment of a club head comprising bumpers. The club head 700 comprises a pair of sole bumpers, including a heel-side sole bumper 774a and a toe-side sole bumper 774b. The sole bumpers 774a, 774b can be substantially similar to the top rail bumpers 672a, 672b described above, but for the sole bumpers 774a, 774b being located proximate the sole 712, rather than the top rail 710.

The sole bumpers 774a, 774b project into the interior cavity 725 from the sole interior surface 721. As illustrated in FIG. 31, the sole bumpers 774a, 774b can curve along the transition between the strike face rear surface 715 and the sole interior surface 721. In such embodiments, the sole bumpers 774a, 774b can contact the strike face rear surface 715. In other embodiments, the sole bumpers 774a, 774b may not contact the strike face rear surface 715. In such embodiments, the sole bumpers 774a, 774b support the pneumatic insert 740 without hindering strike face flexure.

In some embodiments, sole bumpers 774a, 774b are spaced apart by a distance similar to or slightly larger than the pneumatic insert width W_I. As such, the sole bumpers 774a, 774b bound the pneumatic insert 740 on both its heel side and its toe side, near the sole 712. The sole bumpers 774a, 774b prevent the pneumatic insert 740 from moving laterally within the interior cavity 725. The insert width W_I thereby creates an insert retainer that engages the sole bumpers 774a, 774b.

The sole bumpers 774a, 774b allow for precise placement of the pneumatic insert 740 at a desired location. The sole bumpers 774a, 774b can be used as alignment aids to locate the pneumatic insert 740 in the proper heel-to-toe position. In some embodiments, the sole bumpers 774a, 774b can be located just outside, but adjacent to, scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. This particular arrangement locates the pneumatic insert 740 directly rearward of the scoring area. For example, in some embodiments, the heel-side sole bumper 774a can contact the strike face rear surface 715 at a location slightly heelward of the scoring area heel-side boundary plane 1020, whereas the toe-side sole bumper 774b can contact the strike face rear surface 715 at a location slightly toeward of the scoring area toe-side boundary plane 1025. Although FIGS. 30 and 31 illustrate two sole bumpers, other embodiments can include one, two, three, four, five, six, or any other suitable number of sole bumpers.

Similar to the top rail features 672a, 672b described above, the sole bumpers 774a, 774b can be substantially small, thereby retaining the pneumatic insert 740 in the proper position without using a large amount of discretionary mass. Referring to FIG. 30, the sole bumpers 774a, 774b comprise a thickness t_SB measured between opposing surfaces of a given sole bumper. The sole bumpers 774a, 774b further comprise a height H_SB measured perpendicular to the interior surfaces from which the sole bumpers 774a, 774b extend. Both the sole bumper thickness t_SB and the sole bumper height H_SB can be substantially similar to the top rail bumper thicknesses t_TB and the top rail bumper heights H_TB described above.

FIGS. 32 and 33 illustrate another embodiment of a club head comprising bumpers. The club head 800 comprises a pair of back face bumpers, including a heel-side back face bumper 876a and a toe-side back face bumper 876b. The back face bumpers 876a, 876b can be substantially similar to the bumpers described above, but that the back face bumpers 876a, 876b are located on the strike face rear surface 815, rather than the sole 812 or top rail 810.

The back face bumpers 876a, 876b project into the interior cavity 825 from the strike face rear surface 815. In some embodiments, as illustrated in FIGS. 32 and 33, the back face bumpers 876a, 876b extend in a vertical direction from sole 812 to top rail 810. In the illustrated embodiment, the back face bumpers 876a, 876b extend continuously from the sole 812 to top rail 810. In other embodiments, the sole 812 to top rail 810 may extend only a portion of the distance between the top rail 810 and the sole 812 and/or may extend discontinuously between the top rail 810 and the sole 812. In some embodiments, the back face bumpers 876a, 876b may extend horizontally, diagonally, or in any suitable orientation. In some embodiments, the back face bumpers 876a, 876b may be confined to the strike face rear surface 815. In other embodiments, the back face bumpers 876a, 876b may extend along the transition between the strike face rear surface 815 and the top rail interior surface 819 and/or the transition between the strike face rear surface 815 and the sole interior surface.

In some embodiments, the back face bumpers 876a, 876b are spaced apart by a distance similar to or slightly larger than the pneumatic insert width W_I. As such, the back face bumpers 876a, 876b bound the pneumatic insert 840 on both its heel side and its toe side, along at least a portion of the strike face rear surface 815. The back face bumpers 876a, 876b prevent the pneumatic insert 840 from moving laterally within the interior cavity 825. The insert width W_I thereby creates an insert retainer that engages the back face bumpers 876a, 876b.

The back face bumpers 876a, 876b allow for precise placement of the pneumatic insert 840 at a desired location. The back face bumpers 876a, 876b can be used as alignment aids to locate the pneumatic insert 840 in the proper heel-to-toe position. In some embodiments, the back face bumpers 876a, 876b can be located just outside, but adjacent to, scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. This particular arrangement locates the pneumatic insert 840 directly behind of the scoring area. For example, in some embodiments, the heel-side back face bumper 876a can contact the strike face rear surface 815 at a location slightly heelward of the scoring area heel-side boundary plane 1020, whereas the toe-side back face bumper 876b can contact the strike face rear surface 815 at a location slightly toeward of the scoring area toe-side boundary plane 1025. Although FIGS. 32 and 33 illustrate two back face bumpers, other embodiments can include one, two, three, four, five, six, or any other suitable number of back face bumpers.

Similar to the bumpers described above, the back face bumpers 876a, 876b can be substantially small, thereby retaining the pneumatic insert 840 in the proper position without using a large amount of discretionary mass. Referring to FIG. 33, the back face bumpers 876a, 876b comprise a thickness t_BB measured between opposing surfaces of a given back face bumper. The back face bumpers 876a, 876b further comprise a height measured perpendicular to the strike face rear surface 815. The back face bumper thickness t_BB and the back face bumper height can both be substantially similar to the bumper thicknesses and heights described above.

As described above, in some embodiments, one or more of the top rail bumpers, sole bumpers, and/or back face bumpers described above can be combined. FIG. 34 illustrates a club head 900 with a full-cavity bumper comprising a top rail bumper 972, a sole bumper 974, and a back face bumper 976. In the illustrated embodiment, the top rail bumper 972, the sole bumper 974, and the back face bumper 976 connect to one another and extend continuously around the interior cavity 925. As illustrated in FIG. 34, the sole bumper 974 extends up a majority of the rear wall interior surface 923 and terminates near the rear opening 922. Although FIG. 34 illustrates a single full-cavity bumper, other embodiments can include one, two, three, four, five, six, or any other suitable number of full-cavity bumpers.

The one or more full-cavity bumpers provide extra support and retention for the pneumatic insert, as compared to a club head comprising only a top rail bumper, only a sole bumper, or only a back face bumper. Similar to the bumpers described above, the one or more full-cavity bumpers can be substantially small, thereby retaining the pneumatic insert 840 in the proper position without using a large amount of discretionary mass. The full-cavity bumper dimensions (including a full-cavity bumper thickness and a full-cavity bumper height) can be substantially similar to the bumper thicknesses and heights described above.

In some capped hollow-body embodiments, the badge can comprise one or more bumpers in addition to or in replacement of the bumpers described above. As illustrated by FIGS. 35 and 36 the club head 1100 comprises a pair of badge bumpers, including a heel-side badge bumper 1178a and a toe-side badge bumper 1178b. The badge bumpers 1178a, 1178b can be substantially similar to the bumpers described above, but that the badge bumpers 1178a, 1178b are formed by the badge 1150, rather than the club head body 1101.

The badge bumpers 1178a, 1178b extend from the badge interior surface 1152, such that when the badge 1150 is coupled to the body 1101, the badge bumpers 1178a, 1178b project into the interior cavity. In some embodiments, as illustrated in FIG. 271, the badge bumpers 1178a, 1178b extend in a vertical direction between the badge lower edge 1151 and the badge upper edge 1153. In the illustrated embodiment, the badge bumpers 1178a, 1178b extend only a portion of the distance between the badge lower edge 1151 and the badge upper edge 1153. In some embodiments, the badge bumpers 1178a, 1178b may extend the entire distance between the badge lower edge 1151 and the badge upper edge 1153. In other embodiments, the badge bumpers 1178a, 1178b may extend discontinuously between the badge upper edge 1151 and the badge lower edge 1153. In some embodiments, the badge bumpers 1178a, 1178b may extend horizontally, diagonally, or in any suitable direction. In some embodiments, the badge bumpers 1178a, 1178b may be confined to the badge interior surface 1152. In other embodiments, the back face bumpers 1178a, 1178b may extend past the badge perimeter, such that when the badge 1150 is coupled to the body 1101, a portion of the badge bumpers 1178a, 1178b overlaps one or more of the body interior surfaces.

In some embodiments, the badge bumpers 1178a, 1178b are spaced apart by a distance similar to or slightly larger than the pneumatic insert width W_I. As such, the badge bumpers 1178a, 1178b bound the pneumatic insert 1140 on both its heel side and its toe side, along at least a portion of the badge interior surface 1152. The badge bumpers 1178a, 1178b prevent the pneumatic insert 1140 from moving laterally within the interior cavity. The insert width W_I thereby creates an insert retainer that engages the badge bumpers 1178a, 1178b.

The badge bumpers 1178a, 1178b allow for precise placement of the pneumatic insert 1140 at a desired location. The badge bumpers 1178a, 1178b can be used as alignment aids to secure the pneumatic insert 1140 in the proper heel-to-toe position. In some embodiments, badge bumpers 1178a, 1178b can be located just outside, but adjacent to, scoring area heel-side boundary plane 1020 and the scoring area toe-side boundary plane 1025. This particular arrangement locates the pneumatic insert 1140 directly rearward of the scoring area. For example, in some embodiments, the heel-side back face bumper 1178a can extend from the badge interior surface 1152 at a location slightly heelward of the scoring area heel-side boundary plane 1020, whereas the toe-side badge bumper 1178b can extend from the badge interior surface 1152 at a location slightly toeward of the scoring area toe-side boundary plane 1025. Although FIGS. 35 and 36 illustrate two badge bumpers, other embodiments can include one, two, three, four, five, six, or any other suitable number of badge bumpers.

Similar to the bumpers described above, the badge bumpers 1178a, 1178b can be substantially small, thereby retaining the pneumatic insert 1140 in the proper position without using a large amount of discretionary mass. Referring to FIG. 35, the badge bumpers 1178a, 1178b comprise a thickness t_DB measured between opposing surfaces of a given badge bumper. The badge bumpers 1178a, 1178b further comprise a height measured perpendicular to the badge interior surface 1152. The back face bumper thickness t_DB and the badge bumper height can both be substantially similar to the bumper thicknesses and heights described above. Further, the badge bumpers 1178a, 1178b further comprise a length L_DB measured between opposing ends of a given badge bumper. In some embodiments, the badge bumper length L_DB can be between 0.25 and 2.0 inch. In some embodiments, as illustrated in FIG. 35, one or more badge bumpers can comprise a unique length L_DB. In other embodiments, two or more badge bumpers can comprise similar or identical lengths L_DB.

In some embodiments, the badge bumpers 1178a, 1178b can be the only bumpers in the club head. In such embodiments, the badge bumpers 1178a, 1178b retain the pneumatic insert 1140 while contributing a minimal amount of mass, because the badge material (which forms the badge bumpers 1178a, 1178b) is less dense than the body material. In other embodiments, the badge bumpers 1178a, 1178b can be used in addition to and/or combined with any of the other bumpers described herein. In some embodiments, the badge bumpers 1178a, 1178b can be combined with the full body bumpers illustrated in FIG. 34. The combination of the badge bumpers 1178a, 1178b and the full body bumpers can completely encircle the interior cavity in a vertical direction, thereby maximally securing the pneumatic insert in its desired position.

H. Club Head with Multiple Pneumatic Inserts

FIGS. 37A-37B illustrate various embodiments of golf club heads comprising multiple pneumatic inserts. Rather than a single large pneumatic insert, the club head can comprise multiple smaller pneumatic inserts rather than a single large insert. Multiple smaller pneumatic inserts can improve manufacturability by allowing said pneumatic inserts to be installed into tighter or more difficult locations within the cavity. As such, in some embodiments, providing multiple pneumatic inserts can increase the insert contact area. Further, each of the multiple inserts can be separately installed into the cavity through the rear opening. Multiple smaller pneumatic inserts can fit through a smaller rear opening than a single larger pneumatic insert. In some embodiments, therefore, the rear opening area can be reduced, allowing the pneumatic inserts to be secured by a smaller, lighter badge or covering. Further, providing multiple pneumatic inserts can improve embodiments comprising a strut spanning the rear opening. Providing multiple smaller pneumatic inserts can allow for more aggressive strut designs, because the pneumatic inserts can be more easily installed around the strut.

Further, the multiple pneumatic inserts allow localized pressure control across different areas of the club head. In some embodiments, one or more of the multiple pneumatic inserts can be filled with the same pressurized gas as one or more other pneumatic inserts. In other embodiments, one or more pneumatic inserts can be filled with different pressurized gases. In some embodiments, one or more of the multiple pneumatic inserts can comprise similar shapes. In other embodiments, one or more of the multiple pneumatic inserts can be shaped differently. The plurality of pneumatic inserts can be configured improve club head damping and flexure.

In some embodiments, one or more of the multiple pneumatic inserts can comprise the same insert pressure as one or more other pneumatic inserts. In other embodiments, one or more pneumatic inserts can comprise different insert pressures. In some embodiments, one or more pneumatic inserts can comprise a greater insert pressure than one or more other pneumatic inserts to locally stiffen or damp vibrations in a certain portion of the club head. In some embodiments, increasing the insert pressure of one or more pneumatic inserts can allow a corresponding portion of the strike face to be thinned. Any of the pneumatic inserts described in the embodiments below can comprise a greater or lesser insert pressure than any other pneumatic insert.

One or more of the multiple pneumatic inserts can be secured within the cavity by any one or combination of the retainers described herein. In some embodiments, one or more of the multiple pneumatic inserts can be secured solely by a combination of club head retainers or insert retainers, without any additional adhesives or coupling means. In other embodiments, however, the club head can comprise an additional fastening, securing, or adhesive means to secure the one or more pneumatic inserts. The additional fastening, securing, or adhesive means can assure that the smaller multiple pneumatic inserts are secured in the intended position and are prevented from moving within the cavity. In some embodiments, one or more of the multiple pneumatic inserts can be attached to one or more club head interior surfaces via an adhesive, such as an epoxy, an adhesive resin, or a polymer-based tape, such as Very High Bond (VHB™) tape. In some embodiments, because of the small size of the multiple pneumatic inserts, one or more pneumatic inserts can be solely retained by one of the fastening, securing, or adhesive means described above, without any additional retainers.

In some embodiments, the plurality of pneumatic inserts can comprise similar characteristics to the larger, single pneumatic inserts described herein. For example, in some embodiments, the plurality of pneumatic inserts can comprise a combined insert contact area (i.e., the combined insert contact areas of each of the individual pneumatic inserts) within the ranges described above in relation to singular pneumatic inserts. In some embodiments, the plurality of pneumatic inserts can comprise a combined insert contact area, a combined back surface contact area, and/or a combined scoring area back surface contact area within the corresponding ranges relating to singular pneumatic inserts, as described above.

FIGS. 37A and 37B illustrate a club head 1200 comprising multiple vertical pneumatic inserts. The club head 1200 comprises a heel-side pneumatic insert 1270 and a toe-side pneumatic insert 1271. The pneumatic inserts 1270, 1271 can each extend substantially from the sole 1212 to the top rail 1210. The toe-side pneumatic insert 1271 can comprise an insert height H_I greater than that of the heel-side pneumatic insert 1270, because the cavity height H_C is greater proximate the toe 1206 than proximate the heel 1204. In some embodiments, the heel-side pneumatic insert 1270 can be located heelward of the YZ plane, and the toe-side pneumatic insert 1271 can be located toeward of the YZ plane. In some embodiments, the pneumatic inserts 1270, 1271 can be configured to abut each other. In other embodiments, a gap can be provided between the pneumatic inserts 1270, 1271. In such embodiments, the gap can be located approximately behind the strike face center, thereby improving strike face flexure at impact.

In some embodiments, such as the illustrated embodiment of FIGS. 37A and 37B, the pneumatic inserts 1270, 1271 can both be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1270, 1271 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

In some embodiments, as illustrated in FIG. 37A, the club head 1200 comprises a strut 1235. The strut 1235 can be substantially similar to any of the struts described above. As discussed above, the strut 1235 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1270, 1271 can be installed individually into the cavity via the rear opening 1222. In some embodiments, the toe-side pneumatic insert 1271 can be installed before the heel-side pneumatic insert 1270. The toe-side pneumatic insert 1271 can be installed through the largest portion of the rear opening 1222 (i.e., heelward of the strut top end 1236) and then repositioned toeward into its intended final position under the strut 1235. Subsequently, the heel-side pneumatic insert 1270 can be installed and positioned into its intended final position under the strut 1235.

FIGS. 38A and 38B illustrate a club head 1300 comprising multiple horizontal pneumatic inserts. The club head 1300 comprises an upper pneumatic insert 1373 and a lower pneumatic insert 1375. In some embodiments, the upper pneumatic insert 1373 can be located above the XZ plane, and the lower pneumatic insert 1375 can be located below the YZ plane. In the illustrated embodiment, the upper pneumatic insert 1373 comprises an insert top end 1361 that is angled relative to the insert bottom end 1362, so that the top end 1373 follows the contour of the top rail 1310. In some embodiments, the pneumatic inserts 1373, 1375 can be configured to abut each other. In other embodiments, a gap can be provided between the pneumatic inserts 1373, 1375. In such embodiments, the gap can be located approximately behind the strike face center, thereby improving strike face flexure at impact.

In some embodiments, such as the illustrated embodiment of FIGS. 38A and 38B, the pneumatic inserts 1373, 1375 can both be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1373, 1375 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

In some embodiments, as illustrated in FIG. 38A, the club head 1300 comprises a strut 1335. The strut 1335 can be substantially similar to any of the struts described above. As discussed above, the strut 1335 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight The pneumatic inserts 1373, 1375 can be installed individually into the cavity via the rear opening 1322. In some embodiments, the upper pneumatic insert 1373 can be installed before the lower pneumatic insert 1375. The upper pneumatic insert 1373 can be installed through the largest portion of the rear opening 1322 (i.e., below the strut 1335) and then repositioned upward into its intended position under the strut 1235 and proximate the top rail 1310. Subsequently, the lower pneumatic insert 1375 can be installed and positioned into its intended final position under the strut 1235 and proximate the sole 1312.

FIGS. 39A and 39B illustrate a club head 1400 comprising an upper pneumatic insert 1473 and a lower pneumatic insert 1475. The pneumatic inserts 1473, 1475 can be substantially similar to pneumatic inserts 1373, 1375, but for variations in the shape of each pneumatic insert. Referring to FIG. 39B, the lower pneumatic insert 1475 comprises a V-shaped lower insert top end 1461b that corresponds to a complementarily shaped upper insert bottom end 1462a. The lower pneumatic insert 1475 comprises a heel-side top edge 1476a proximate the lower insert heel end 1463b and a toe-side top edge 1476b proximate the lower insert toe end 1464b. The heel-side top edge 1476a and the toe-side top edge 1476b meet at a nadir 1478. The heel-side top edge 1476a is angled soleward from the lower insert heel end 1463b to the nadir 1478. The toe-side top edge 1476b is angled soleward from the lower insert toe end 1464b to the nadir 1478. The upper pneumatic insert 1473 comprises a heel-side bottom edge 1474a proximate the upper insert heel end 1463a and a toe-side bottom edge 1474b proximate the upper insert toe end 1464a. The heel-side bottom edge 1474a and the toe-side bottom edge 1474b meet at a bottom end apex 1479. The heel-side bottom edge 1474a is angled soleward from the upper insert heel end 1464a to the bottom end apex 1479. the toe-side bottom edge 1474b is angled soleward from the upper insert toe end 1464a to the bottom end apex 1479. In some embodiments, the pneumatic inserts 1473, 1475 can be configured to abut each other. In other embodiments, a gap can be provided between the pneumatic inserts 1473, 1475. In such embodiments, the gap can be located approximately behind the strike face center, thereby improving strike face flexure at impact.

As illustrated in FIGS. 39A and 39B, the pneumatic inserts 1473, 1475 can both be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1473, 1475 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

As illustrated in FIG. 39A, the club head 1400 can comprise a strut 1435. The strut 1435 can be substantially similar to any of the struts described above. As discussed above, the strut 1435 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1473, 1475 can be installed individually into the cavity via the rear opening 1422. In some embodiments, the upper pneumatic insert 1473 can be installed before the lower pneumatic insert 1475. The upper pneumatic insert 1473 can be installed through the largest portion of the rear opening 1422 (i.e., below the strut 1435) and then repositioned upward into its intended position proximate the top rail 1410. Subsequently, the lower pneumatic insert 1475 can be installed under the strut 1435 and positioned into its intended final position proximate the sole 1412.

FIGS. 40A and 40B illustrate a club head 1500 comprising an upper pneumatic insert 1573 and a lower pneumatic insert 1575. The lower pneumatic insert 1575 comprises an “L”-shape in which a lower insert base 1582 extends in a heel-to-toe direction along sole 1512 and a lower insert arm 1583 extends upward from the lower insert base 1582 to the top rail 1510. In the illustrated embodiment, the lower insert arm 1583 extends upward from a heel side of the lower insert base 1582, however, in other embodiments, the lower insert arm 1583 can extend upward from the toe side of the lower insert base 1582 or from a center of the lower insert base 1582. The upper pneumatic insert 1573 can be nested within the elbow of the “L”-shaped lower insert 1575. In the illustrated embodiment, the upper insert bottom end 1562a is proximate the lower insert base 1582 and the upper insert heel end 1563a is proximate the lower insert arm 1583. In some embodiments, the pneumatic inserts 1573, 1575 can be configured to abut each other. In other embodiments, a gap can be provided between the pneumatic inserts 1573, 1575. In such embodiments, the gap can be located approximately behind the strike face center, thereby improving strike face flexure at impact.

As illustrated in FIGS. 40A and 40B, the pneumatic inserts 1573, 1575 can both be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1573, 1575 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

As illustrated in FIG. 40A, the club head 1500 can comprise a strut 1535. The strut 1535 can be substantially similar to any of the struts described above. As discussed above, the strut 1535 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1573, 1575 can be installed individually into the cavity via the rear opening 1522. In some embodiments, the upper pneumatic insert 1573 can be installed before the lower pneumatic insert 1575. The upper pneumatic insert 1573 can be installed through the largest portion of the rear opening 1522 (i.e., below the strut 1535) and then repositioned upward and toeward into its intended position proximate the top rail 1510. Subsequently, the lower pneumatic insert 1575 can be installed and positioned into its intended final position proximate the sole 1512. The “L”-shape of the lower pneumatic insert 1575 allows it to fit easily through the rear opening 1522. As illustrated in FIG. 40A, the lower insert base 1582 can pass heelward of the strut bottom end 1537, while the lower insert arm 1583 can pass underneath the strut top end 1536.

FIGS. 41A and 41B illustrate a club head 1600 comprising an upper pneumatic insert 1673 and a lower pneumatic insert 1675. The pneumatic inserts 1673, 1675 can be substantially similar to pneumatic inserts 1373, 1375 but for variations in the shape of each pneumatic insert. Referring to FIG. 39B, the lower pneumatic insert 1675 comprises an arcuate lower insert top end 1661b that corresponds to a complementarily shaped upper insert bottom end 1662a. The center of the lower insert top end 1661b comprises a convex surface protruding outward from the remainder of the lower pneumatic insert 1675. Conversely, the center of the upper insert bottom end 1662a comprises a concave surface shaped to receive the lower insert top end 1661b. In some embodiments, the pneumatic inserts 1673, 1675 can be configured to abut each other. In other embodiments, a gap can be provided between the pneumatic inserts 1673, 1675. In such embodiments, the gap can be located approximately behind the strike face center, thereby improving strike face flexure at impact.

As illustrated in FIGS. 41A and 41B, the pneumatic inserts 1673, 1675 can both be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1673, 1675 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

As illustrated in FIG. 41A, the club head 1600 can comprise a strut 1635. The strut 1635 can be substantially similar to any of the struts described above. As discussed above, the strut 1635 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1673, 1675 can be installed individually into the cavity via the rear opening 1622. In some embodiments, the upper pneumatic insert 1673 can be installed before the lower pneumatic insert 1675. The upper pneumatic insert 1673 can be installed through the largest portion of the rear opening 1622 (i.e., below the strut 1635) and then repositioned upward into its intended position proximate the top rail 1610. Subsequently, the lower pneumatic insert 1675 can be installed under the strut 1635 and positioned into its intended final position proximate the sole 1612.

FIGS. 42A and 42B illustrate a club head 1700 comprising an upper pneumatic insert 1773 and a lower pneumatic insert 1775. The upper pneumatic insert 1773 can be substantially smaller than the lower pneumatic insert 1775. The upper pneumatic insert 1773 can be sized to fit solely within the top rail undercut (as described in detail above). The lower pneumatic insert 1775 can be substantially larger and can extend the remainder of the distance from the upper pneumatic insert 1773 to the sole 1712. The present configuration can allow for greater vibration damping in the top rail 1710, which is typically a region that experiences dominant vibrations. In some embodiments, the pneumatic inserts 1773, 1775 can be configured to abut each other. In other embodiments, a gap can be provided between the pneumatic inserts 1773, 1775. In such embodiments, the gap can improve strike face flexure at impact.

As illustrated in FIGS. 42A and 42B, the pneumatic inserts 1773, 1775 can both be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1773, 1775 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

As illustrated in FIG. 42A, the club head 1700 can comprise a strut 1735. The strut 1735 can be substantially similar to any of the struts described above. As discussed above, the strut 1735 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1773, 1775 can be installed individually into the cavity via the rear opening 1722. In some embodiments, the upper pneumatic insert 1773 can be installed before the lower pneumatic insert 1775. The upper pneumatic insert 1773 can be installed through the largest portion of the rear opening 1722 (i.e., below the strut 1735) and then repositioned upward into its intended position proximate the top rail 1710. Subsequently, the lower pneumatic insert 1775 can be installed under the strut 1735 and positioned into its intended final position proximate the sole 1712.

FIGS. 43A and 43B illustrate a club head 1800 comprising a heel-side pneumatic insert 1870, an upper toe-side pneumatic insert 1871a, and a lower toe-side pneumatic insert 1871b. The upper toe-side pneumatic insert 1871a and the lower toe-side pneumatic insert 1871b can be substantially smaller than the heel-side pneumatic insert 1870, to allow for easier installation. In some embodiments, one or more of the pneumatic inserts 1870, 1871a, 1871b can be configured to abut each other. In other embodiments, a gap can be provided between one or more of the pneumatic inserts 1870, 1871a, 1871b. In such embodiments, one or more of the gaps can be located approximately behind the strike face center, thereby improving strike face flexure at impact.

As illustrated in FIGS. 43A and 43B, the pneumatic inserts 1870, 1871a, 1871b can each be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1870, 1871a, 1871b can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

As illustrated in FIG. 43A, the club head 1800 can comprise a strut 1835. The strut 1835 can be substantially similar to any of the struts described above. As discussed above, the strut 1835 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1870, 1871a, 1871b can be installed individually into the cavity via the rear opening 1822. In some embodiments, the upper toe-side pneumatic insert 1871a can be installed first, followed by the lower toe-side pneumatic insert 1871b, and finally the heel-side pneumatic insert 1870. The upper toe-side pneumatic insert 1871a can be installed through the largest portion of the rear opening 1822 (i.e., below the strut 1835) and then repositioned upward and toeward into its intended position proximate the top rail 1810 and the toe 1806. The lower toe-side pneumatic insert 1871b can then be installed below the strut 1835 and then reposition soleward and toeward into its intended position proximate the sole 1812 and the toe 1806. Finally, the heel-side pneumatic insert 1870 can be installed under the strut 1835 and positioned into its intended final position.

FIGS. 44A and 44B illustrate a club head 1900 comprising an upper pneumatic insert 1973, a central pneumatic insert 1977, and a lower pneumatic insert 1975. The upper pneumatic insert 1973 can be sized to fit solely within the top rail undercut (as described in detail above). The lower pneumatic insert 1975 can be sized to fit solely within the lower interior undercut (as described in detail above). The central pneumatic insert 1977 can be located approximately behind the strike face center and the can extend between the upper pneumatic insert 1973 and the lower pneumatic insert 1975. The present configuration can allow for greater vibration damping in the top rail 1910 and/or the sole 1912. In some embodiments, one or more of the pneumatic inserts 1973, 1975, 1977 can be configured to abut each other. In other embodiments, a gap can be provided between one or more of the pneumatic inserts 1973, 1975, 1977. In such embodiments, the one or more gaps can improve strike face flexure at impact.

As illustrated in FIGS. 44A and 44B, the pneumatic inserts 1973, 1975, 1977 can each be located substantially behind the scoring area. In other embodiments, the pneumatic inserts 1973, 1975, 1977 can combine to occupy a greater portion of the cavity that extends beyond the scoring area.

As illustrated in FIG. 44A, the club head 1900 can comprise a strut 1935. The strut 1935 can be substantially similar to any of the struts described above. As discussed above, the strut 1935 can act as a vibration damping feature, a club head retainer, and/or a perimeter weight. The pneumatic inserts 1973, 1975, 1977 can be installed individually into the cavity via the rear opening 1922. In some embodiments, the upper pneumatic insert 1973 can be installed first, followed by the lower pneumatic insert 1975, and finally the central pneumatic insert 1977. The upper pneumatic insert 1973 can be installed through the largest portion of the rear opening 1922 (i.e., below the strut 1935) and then repositioned upward into its intended position proximate the top rail 1810. The lower pneumatic insert 1975 can then be installed below the strut 1935 and then reposition soleward into its intended position proximate the sole 1812. Finally, the central pneumatic insert 1977 can be installed under the strut 1935 and positioned into its intended final position proximate the strike face center.

III. Additional Insert Embodiments

Described below are various embodiments of pneumatic inserts that can be applied to any of the cavity-back, capped hollow-body, or fully enclosed hollow-body club heads described above. Further, any of the pneumatic insert embodiments described below can be provided in combination with any one or more of the retainers or additional coupling members described herein.

In some embodiments, as shown in FIGS. 45-48, 51-52, 57-85, and 67-74, the golf club head can comprise a pneumatic insert with a localized response. The pneumatic inserts (hereafter alternately referred to as “the localized pneumatic inserts”) are shaped to contact selected portions of the club head interior surfaces and/or selected areas of the strike face rear surface. In some embodiments, the localized inserts damp high-vibration club head areas without contact areas that experience less significant vibrations. The localized pneumatic inserts provide damping and reinforcing effects while creating discretionary mass over a larger insert that occupies a greater portion of the cavity and without excessively hindering club head flexibility.

Furthermore, the localized pneumatic inserts can be configured to have an operative state and a compressed state. In the operative state, the localized pneumatic insert is disposed within the club head cavity and assumes a normal or expanded configuration having a volume, footprint, and dimensions to function as intended as the user swings the golf club through contact with a golf ball. In some embodiments, the operative state of the localized pneumatic insert is associated with conditions in which no exterior forces are applied to the insert. The localized pneumatic insert is constructed to allow applied exterior forces to move it to the compressed state, in which the volume, footprint, and/or dimensions of the insert are reduced. Constricting or minimizing at least one dimension of the pneumatic insert allows for easier insertion into the club head cavity.

To facilitate moving between operative and compressed states, the localized pneumatic inserts can comprise a flexure region. The flexure region defines a section of the localized pneumatic insert that facilitates controlled bending, twisting, or pivoting of the pneumatic insert along a predetermined axis or location. As discussed above, the contorting of the pneumatic insert allows for easier insertion of the pneumatic insert into the golf club cavity, thereby improving assembly and manufacturability. In many embodiments, the flexure region can separate a first side and a second side of the pneumatic insert, wherein the bending, twisting, or pivoting occurs between the pneumatic insert first side and the pneumatic insert second side. In other embodiments, the flexure region can be proximate to one or more voids, cavities, or spaces along the pneumatic insert to promote structural discontinuity and to allow for the transition between the compressed state and the operative state. Furthermore, the flexure region may comprise reduced material thickness, a fold line, a hinge-like structure, or a segment with flexible seams or joints.

Any of the localized pneumatic inserts described below can be secured within the cavity by any one or combination of the retainers described herein. In some embodiments, the localized pneumatic insert can be secured solely by a combination of club head retainers or insert retainers, without any additional adhesives or coupling means. In other embodiments, however, the club head can comprise an additional fastening, securing, or adhesive means to secure the localized pneumatic insert. The additional fastening, securing, or adhesive means can assure that the localized pneumatic insert, which may not be large enough to be fully secured by club head or insert retainers, is secured in the intended position and prevented from moving within the cavity. In some embodiments, the localized pneumatic insert can be attached to one or more club head interior surfaces via an adhesive, such as an epoxy, an adhesive resin, or a polymer-based tape, such as Very High Bond (VHB™) tape. In some embodiments, the localized pneumatic insert can be solely retained by a one of the fastening, securing, or adhesive means described above, without any additional retainers.

In some embodiments, the localized pneumatic insert can comprise similar characteristics to the pneumatic inserts described herein. For example, in some embodiments, the localized pneumatic insert can comprise an insert contact area, a back surface contact area, and/or a scoring area back surface contact area within the corresponding ranges described above.

I. Pneumatic Insert with Aperture

FIG. 45 illustrates a club head 2100 comprising a pneumatic insert 2140 with a central aperture 2141. The central aperture 2141 extends in a front-to-back direction through the entirety of the pneumatic insert 2140. The central aperture 2141 extends from the insert forward surface 2146 to the insert rear surface 2148. In some embodiments, the central aperture 2141 can correspond to the location of the strike face center. The central aperture 2141 can also accommodate a variable face thickness or thickened central portion of the strike face, if provided. The pneumatic insert 2140 can effectively damp vibrations occurring near the strike face perimeter, while the central aperture 2141 allows the strike face to flex near the strike face center. The pneumatic insert 2140 comprising the central aperture 2141 thereby improves sound and feel as well as ball flight performance. Although the central aperture 2141 is illustrated comprising a circular shape, the central aperture 2141 can be square, triangular, rectangular, elliptical, hexagonal, octagonal, or any other suitable shape.

Furthermore, a flexure region 2133 defines the region of the pneumatic insert 2140 containing the central aperture 2141. As illustrated in FIG. 45, the flexure region 2133 defines the region of the pneumatic insert 2140 between a heel region 2163 and a toe region 2164. The flexure region 2133 allows the pneumatic insert 2140 to flex or deform, thereby promoting the transition between a compressed state and an operative state. This flexing or deformation of the pneumatic insert 2140 may allow the shape of the central aperture 2141 to change during compression. The compressed state allows for easy insert insertion into the cavity 2125, and the operative state defines the insertion orientation after the insert is placed within the cavity 2125. Moreover, the pneumatic insert 2140 can comprise similar features to the previously mentioned inserts.

In many embodiments, as illustrated in FIG. 67, the pneumatic insert 2140 comprises a web 2145 within the central aperture 2141. The web 2145 can be a thin, pliable structure made of the same material as the membrane. The web 2145 can comprise a woven, perforated, mesh-like, continuous, seamless, or interconnected design to maintain flexibility and structural integrity within the central aperture 2141. Although FIG. 67 illustrates an elliptical central aperture 2141, the central aperture 2141 can be square, triangular, rectangular, elliptical, hexagonal, octagonal, or any other suitable shape.

Moreover, as illustrated in FIG. 68, the web 2145 may include a pinched column 2193 in place of the central aperture 2141, which provides structural support to the pneumatic insert 2140. This pinched column 2193 forms a region of the pneumatic insert 2140 within the pneumatic insert perimeter 2143 where the pneumatic insert forward surface 2146 is connected to the pneumatic insert rear surface 2148. The pinched column 2193 creates a continuous, singular web 2145 connected to and positioned between the pneumatic insert forward surface 2146 and the pneumatic insert rear surface 2148. The pinched column 2193 serves a structural role by reinforcing the pneumatic insert 2140 and preventing excessive expansion or inflation beyond its intended limits, particularly at regions surrounding the pinched column 2193. In other words, the pinched column 2193 enables the pneumatic insert 2140 to withstand greater internal pressure without “ballooning” or expanding unevenly or distorting, maintaining its intended shape and structural integrity at the perimeter. Additionally, the pinched column 2193 helps regulate the internal volume of the pneumatic insert 2140, ensuring controlled deformation and maintaining structural integrity under pressure. In some embodiments, the pinched column 2193 further stabilizes the thickness of the pneumatic insert 2140 upon inflation, promoting uniform expansion and better damping and vibration characteristics. Additionally, the pinched column 2193 can be positioned near or substantially aligned with the ideal impact position on the strike face, thereby enhancing structural support of the strike face.

The pinched column 2193 maintains more constant overall dimensions of the pneumatic insert over a broader range of insert pressures. The membrane used to form the pneumatic insert is made of a flexible material that can change dimensions based on inflation pressure. Accordingly, the pneumatic insert has an intended inflation pressure, typically 0.1 to 30 psi, that is associated with desired dimensional sizes. The volume of the pneumatic insert, however, is relatively small, and therefore when being inflated during assembly is prone to sudden increase above the intended pressure level. In some embodiments, overinflation by as little as 0.1 psi may cause the pneumatic insert to excessively increase dimensions. The pinched column 2193 resists excessive expansion of the insert. For example, a height of the pneumatic insert may increase by less than 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, or 45%, for each additional 0.1 psi that the pneumatic insert 2140 is inflated above the intended pressure level, such that the pneumatic insert 2140 can still fit within the interior cavity of the golf club head. Alternatively, pneumatic inserts devoid of a pinched column 2193 or any other interstitial feature may increase in height by more than 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% when subjected to a pressure increase of 0.1 psi beyond its intended inflation pressure. Pneumatic insert 2140 can be inflated slightly beyond its intended inflation pressure without drastically increasing dimensions. Furthermore, in some embodiments, the pinched column 2193 facilitates a roughly linear relationship between the insert pressure and the insert dimensions. In other embodiments, the insert dimensions are roughly constant regardless of the insert pressure due to the structural role of the pinched column 2193.

In many embodiments, the pinched column 2193 is achieved using a thermal bonding process wherein the pneumatic insert forward surface 2146 and the pneumatic insert rear surface 2148 are bonded using heat and pressure to create the web 2145. In many cases, the thermal bonding process can be defined by a spot weld process to connect the pneumatic insert forward surface 2146 and the pneumatic insert rear surface 2148. Thermally bonding these surfaces creates the single layer web 2145 positioned between and connected to both the pneumatic insert forward surface 2146 and the pneumatic insert rear surface 2148.

The club head 2100 comprises a plurality of retainers. As illustrated in FIG. 45, the insert top end 2161 engages a top rail undercut 2130, the insert bottom end 2162 engages a lower interior undercut 2131, and the pneumatic insert 2140 further comprises a rear protrusion 2167 that engages a mass pad top surface 2184. In some embodiments, pneumatic insert 2140 is secured solely by the plurality of retainers. In other embodiments, the pneumatic insert 2140 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 2146.

J. Ring-Shaped Pneumatic Insert

FIG. 46 illustrates a club head 2200 comprising a ring-shaped pneumatic insert 2240. The ring-shaped pneumatic insert 2240 comprises a central aperture 2241 that can be substantially similar to central aperture 2141 described above. Rather than extending all the way from the top rail 2210 to the sole 2212, the ring-shaped pneumatic insert 2240 terminates at an outer perimeter 2243 that substantially follows the contour of the central aperture 2241, thereby forming a ring shape. Although the ring-shaped pneumatic insert 2240 is illustrated comprising a circular shape, the ring-shaped pneumatic insert 2240 can be square, triangular, rectangular, elliptical, hexagonal, octagonal, or any other suitable shape.

Furthermore, a flexure region 2233 defines the region of the ring-shaped pneumatic insert 2240 containing the central aperture 2241. As illustrated in FIG. 46, the flexure region 2233 defines the region of the ring-shaped pneumatic insert 2240 between a heel region 2263 and a toe region 2264. The flexure region 2233 allows the ring-shaped pneumatic insert 2240 to flex or deform, thereby promoting the transition between a compressed state and an operative state. This flexing or deformation of the ring-shaped pneumatic insert 2240 may allow the shape of the central aperture 2241 to change during compression. In many embodiments, flexure region 2233 is configured to bring the heel region 2263 and the toe region 2264 closer together in the compressed state. Moreover, due to the substantially symmetrical orientation of the ring-shaped pneumatic insert 2240, the flexure region 2233 can be titled between 0 and 360 degrees, such that opposing portions of the ring-shaped pneumatic insert 2240 are closer together in the compressed state than in the operative state. The compressed state allows for easy insert insertion into the cavity 2225 and the operative state defines the insertion orientation after the insert is placed within the cavity 2225. Moreover, the ring-shaped pneumatic insert 2240 can comprise similar features to the previously mentioned inserts.

In some embodiments, the central aperture 2241 can correspond to the location of the strike face center. The ring-shaped pneumatic insert 2240 can be configured primarily damp vibrations occurring near the strike face center, while using a minimal amount of mass and providing minimal resistance against strike face flexure. The ring-shaped pneumatic insert 2240 can occupy a very small proportion of the cavity. In some embodiments, the ring-shaped pneumatic insert 2240 can occupy less than 30%, less than 25%, less than 20%, less than 15%, less than 10%, or less than 5% of the cavity volume.

The club head 2200 comprises a plurality of retainers. As illustrated in FIG. 46, the insert bottom end 2262 engages a lower interior undercut 2231, and the ring-shaped pneumatic insert 2240 further comprises a rear protrusion 2267 that engages a mass pad top surface 2284. In some embodiments, the ring-shaped pneumatic insert 2240 is secured solely by the plurality of retainers. In other embodiments, the ring-shaped pneumatic insert 2240 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 2246.

K. Arched Pneumatic Insert

FIG. 47 illustrates a club head 2300 comprising an arched pneumatic insert 2340. The arched pneumatic insert 2340 comprises a heel-side leg 2368a and a toe-side leg 2368b connected by a bridge 2369 near the top rail 2310. A void 2385 is formed between the heel-side leg 2368a and toe-side leg 2368b, and the heel-side leg 2368a and toe-side leg 2368b each comprise free ends 2386a, 2386b near the sole 2312 that are not connected. The arched configuration allows the pneumatic insert 2340 to flex such that the legs 2368a, 2368b pivot about the bridge 2369. The arched pneumatic insert 2340 can flex in this way during use or during insert installation. In some embodiments, the void 2385 can correspond to the location of the strike face center. The pneumatic insert 2340 can effectively damp vibrations occurring near the strike face perimeter, while the void 2385 allows the strike face to flex near the strike face center.

Furthermore, a flexure region 2333 defines the region of the arched pneumatic insert 2340 containing the void 2385. As illustrated in FIG. 47, the flexure region 2333 defines the region of the arched pneumatic insert 2340 between a heel region 2363 and a toe region 2364. The heel region 2363 defines at least a portion of the heel-side leg 2368a and the toe region 2364 defines at least a portion of the toe-side leg 2368b. The flexure region 2333 allows the arched pneumatic insert 2340 to flex or deform, thereby promoting the transition between a compressed state and an operative state. As previously mentioned, the flexure region 2333 of the arched pneumatic insert 2340 allows the legs 2368a, 2368b to pivot about the bridge 2369. In the operative state, substantially no exterior forces are acting on the arched pneumatic insert 2340, such that the legs 2368a, 2368b are not pinched or stretched. As such, the operative state defines an operative state width of the arched pneumatic insert 2340, measured from a heel side of the heel-side free end 2386a and a toe side of the toe-side free end 2386b. Alternatively, in the compressed state, the legs 2368a, 2368b pivot about the bridge 2369, thereby bringing the free ends 2386a, 2386b closer together. As such, the compressed state defines a compressed state width, measured from the heel side of the heel-side free end 2386a and the toe side of the toe-side free end 2386b. The operative state width is greater than the compressed state width, due to the pinched configuration of the legs 2368a, 2368b in the compressed state. The compressed state width defines a constricted overall volume of the arched pneumatic insert 2340, allowing for easy insertion into the cavity 2325.

The club head 2300 comprises a plurality of retainers. As illustrated in FIG. 47, the insert top end 2361 engages a top rail undercut 2330, and the free ends 2386a, 2386b of each leg engage a lower interior undercut 2331. The arched pneumatic insert 2340 further comprises a rear protrusion 2367 on each leg 2368a, 2368b that engages a mass pad top surface 2384.

In some embodiments, the arched pneumatic insert 2340 is secured solely by the plurality of retainers. In other embodiments, the arched pneumatic insert 2340 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 2346.

L. Keyhole Pneumatic Insert

In many embodiments, as best illustrated in FIG. 69, the club head 4400 comprises a keyhole insert 4440. The flexure region 4433 of the keyhole insert 4440, defined below, promotes the transition between a compressed state and an operative state. The compressed state allows for easy insert insertion into the cavity 4425 and the operative state defines the insertion orientation after the insert is placed within the cavity 4425. Moreover, the keyhole insert 4440 can comprise similar features to the previously mentioned inserts.

Specifically, the keyhole insert 4440 comprises a central aperture 4441, as well as a heel-side leg 4468a and a toe-side leg 4468b. As previously mentioned, a void 4485 is formed between the heel-side leg 4468a and toe-side leg 4468b. Further, the heel-side leg 4468a and toe-side leg 4468b comprise a heel-side free end 4486a and a toe-side free end 4486b, respectively. The heel-side free end 4486a and the toc-side free end 4486b are located proximate to a sole side of the keyhole insert 4440 and are not connected. Moreover, the toc-side leg 4468b comprises a toe-side intermediate wall 4465b and the heel-side leg 4468a comprises a heel-side intermediate wall 4465a opposite the toe-side intermediate wall 4465b. The heel-side leg 4468a and the toe-side leg 4468b face inwards toward the void 4485. The keyhole insert 4440 further comprises a central aperture 4441 positioned along the void 4485 opposite the free ends 4468a, 4468b. The central aperture 4441 further defines a penannular wall between and connecting the heel-side intermediate wall 4465a and the toc-side intermediate wall 4465b. The combination of the central aperture 4441 and the void 4485 between heel-side leg 4468a and toe-side leg 4468b creates a keyhole shape. Moreover, the keyhole shape is defined by the penannular wall, the heel-side intermediate wall 4465a, and the toc-side intermediate wall 4465b. In such embodiments, the flexure region 4433 defines the region of the keyhole insert 4440 between a heel region 4463 and a toc region 4464. The heel region 4463 defines at least a portion of the heel-side leg 4468a and the toe region 4464 defines at least a portion of the toe-side leg 4468b. The flexure region 4433 further defines the central aperture 4441, the void 4485, the toe-side intermediate wall 4465b, and the heel-side intermediate wall 4465a. The flexure region allows the pneumatic insert 4440 to flex such that the legs 4468a, 4468b pivot about the central aperture 4441. Like the arched pneumatic insert 2340, the keyhole insert 4440 can flex during use or during insert installation. In some embodiments, the central aperture 4441 can correspond to the location of the strike face center. The keyhole insert 4440 can effectively damp vibrations occurring near the strike face perimeter, while the void 4485 and the central aperture 4441 allow the strike face to flex near the strike face center.

As previously mentioned, the flexure region 4433 of the keyhole insert 4440 allows the legs 4468a, 4468b to pivot about the central aperture 4441. In the operative state, substantially no exterior forces are acting on the keyhole insert 4440, such that the legs 4468a, 4468b are not pivoted, pinched, or stretched. As such, as illustrated in FIG. 70A, the operative state defines an operative state width OS_W of the keyhole insert 4440, measured from a heel side of the heel-side free end 4486a and a toe side of the toe-side free end 4486b when the keyhole insert 4440 is in the operative state. Alternatively, in the compressed state, the legs 4468a, 4468b to pivot about the central aperture 4441, thereby shrinking the size of the void 4485 and bringing the free ends 4486a, 4486b closer together. As such, as illustrated in FIG. 70B, the compressed state defines a compressed state width CS_W, measured from the heel side of the heel-side free end 4486a and the toe side of the toc-side free end 4486b when the keyhole insert 4440 is in the compressed state. The operative state width OS_W is greater than the compressed state width CS_W, due to the pinched configuration of the legs 4468a, 4468b in the compressed state. The compressed state width CS_W defines a constricted overall volume of the keyhole insert 4440, allowing for easy insertion into the cavity 4425.

As described above, the difference between the operative state width OS_W and the compressed state width CS_W allows for insertion into the cavity. In some embodiments, the keyhole insert operative state width OS_W can be between 0.75 and 2.00 inches. In some embodiments, the operative state width OS_W can be between 0.75 and 1.00 inch, 1.00 inch and 1.25 inches, 1.25 inches and 1.50 inches, 1.50 inches and 1.75 inches, or 1.75 inches and 2.00 inches. Moreover, the operative state width OS_W can be between 0.125 inch and 0.75 inch greater than the compressed state width CS_W. In such embodiments, the operative state width OS_W can be between 0.125 inch and 0.25 inch, 0.25 inch and 0.375 inch, 0.375 and 0.50 inch, 0.50 inch and 0.625 inch, or 0.625 inch and 0.75 inch greater than the compressed state width CS_W. As previously mentioned, the difference between the operative state width OS_W and the compressed state width CS_W promotes easy insertion into the club head cavity 4425.

Additionally, the central aperture 4441 and void 4485 can comprise a variety of shapes, sizes, and orientations. In many embodiments, the central aperture can comprise a relatively circular shape, as illustrated in FIG. 69. In other embodiments, the central aperture 4441 can comprise an ovular, elliptical, rectangular, polygonal, or irregular shape. A central aperture width CA_W, measured along a horizontal plane between opposing ends of the central aperture, can be between 0.20 inch and 1.00 inch. In other embodiments, the central aperture width CA_W can be defined by a central aperture diameter. The central aperture diameter can bet between 0.20 and 1.00 inches. Moreover, the void width V_W, illustrated in FIG. 70A, measured as the shortest distance between the legs 4468a, 4468b is smaller than the central aperture width CA_W. Particularly, the void width V_W can be between 0.125 and 0.75 inches. As described above, the keyhole-like shape of the keyhole insert 4540 is created due to the size difference between the central aperture 4441 and the void 4485. The larger width or diameter of the central aperture 4441 allows for ample insert bending between the compressed and operative state, while the smaller void width V_W creates more contact area between the keyhole insert forward surface 4446 and the strike face rear surface. This improves club head vibration control and enhances the sound and feel of the club head. Moreover, the central aperture width CA_W and the void width V_W provide space for free ends 4486a and 4486b to move between the compressed state and the operative state. Therefore, a larger central aperture width CA_W and void width V_W allow for a smaller compressed state width CS_W, thereby allowing for easy insertion into the cavity 4425.

As previously mentioned, a smaller void width V_W, relative to the central aperture width CA_W, creates a greater contact area between the strike face rear surface and the forward surface 4546 of the keyhole insert 4540. As discussed above, the contact area between the pneumatic insert and the club head interior surfaces restricts the vibration of said surfaces. In general, club head vibrations are most effectively dampened in areas contacted by the pneumatic insert, and a greater overall contact area between the pneumatic insert and club head interior surfaces may improve the overall club head vibrational response. Moreover, sufficient contact area between the pneumatic insert and club head interior surfaces damps vibrations without overly restricting club head flexibility, thereby promoting ball speed and launch characteristics.

As such, the contact area can be expressed as a function of the size and orientation of the flexure region 4433 and its orientation relative to the club head interior surfaces. In some embodiments, the flexure region 4433 can comprise a contact portion and a non-contact portion. The contact portion defines the region of the keyhole insert 4440 between the heel region 4463 and the toe region 4464 that is in contact with the strike face rear surface. The non-contact portion defines the central aperture 4441 and the void 4485, or the portion within the flexure region 4433 that is not in contact with the strike face rear surface. In some embodiments, a flexure region contact portion area can be greater than 60% of the overall flexure region area. In some embodiments, the flexure region contact portion area can be between 60% and 70%, between 70% and 80%, between 80% and 99%, or between 90% and 100% of the overall flexure region area. In some embodiments, the flexure region contact portion area can be greater than 60%, greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, or greater than 95% of the overall flexure region area. In some embodiments, the flexure region contact portion area can be approximately 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of the overall flexure region area.

In many embodiments, the club head can comprise a keyhole insert 4540 further including a web 4545 disposed within the central aperture 4541 and void 4585, as illustrated in FIG. 70. As discussed above, the web 4545 can be a thin, pliable structure made of the same membrane material as the connected keyhole insert 4540. The web 4545 can comprise a woven, perforated, mesh-like, continuous, seamless, or interconnected design to maintain flexibility and structural integrity within the central aperture 4541 and void 4585. In some embodiments, the web 4545 can be flush with the insert forward surface 4546, such that the central aperture 4541 and void 4585 are only visible from the insert rear surface 4548. In other embodiments, the web 4545 can be flush with the insert rear surface 4548, such that the central aperture 4541 and void 4585 are only visible from the insert forward surface 4546. In even further embodiments, the web 4545 is positioned between the insert forward surface 4546 and the insert rear surface 4548, such that the central aperture 4541 and void 4585 are visible from both the insert forward surface 4546 and the insert rear surface 4548.

The club head 4400 can further comprise a plurality of retainers. In some embodiments, the keyhole insert 4440 is secured solely by the plurality of retainers. In other embodiments, the keyhole insert 4400 is further secured by an additional coupling means, such as a polymer-based tape applied to the keyhole insert forward surface 4446.

M. X-Shaped Pneumatic Insert

FIG. 48 illustrates a club head 2400 comprising an X-shaped pneumatic insert 2440. The X-shaped pneumatic insert 2440 comprises center portion 2469 and a plurality of legs. The X-shaped pneumatic insert 2440 comprises an upper heel-side leg 2468a, and upper toe-side leg 2468b, a lower heel-side leg 2488a, and a lower toe-side leg 2488b. The upper heel-side leg 2468a extends from the center portion 2469 towards the top rail 2410 and the heel 2404. The upper toe-side leg 2468b extends from the center portion 2469 towards the top rail 2410 and the toe 2406. The lower heel-side leg 2488a extends from the center portion 2469 towards the sole 2412 and the heel 2404. The lower toe-side leg 2488b extends from the center portion 2469 towards the sole 2412 and the toe 2406. A void 2485 can be formed between each adjacent leg. The X-shaped configuration allows the legs 2468a, 2468b, 2488a, 2488b to flex, thereby improving overall insert flexibility, both during club head use and during insert installation. In some embodiments, the center portion 2469 can correspond to the location of the strike face center, such that the X-shaped pneumatic insert 2440 contacts a large portion of the strike face rear surface around the strike face center. The pneumatic insert 2440 improves vibration damping and structural reinforcement of high-vibration and high-deflection areas near the strike face center.

Furthermore, a flexure region 2433 defines the region of the X-shaped pneumatic insert 2440 containing the center portion 2469. As illustrated in FIG. 48, the flexure region 2433 defines the region of the X-shaped pneumatic insert 2440 between a heel region 2463 and a toe region 2464. The heel region 2463 defines at least a portion of the upper heel-side leg 2468a and the lower heel-side leg 2488a. The toe region 2464 defines at least a portion of the upper toe-side leg 2468b and the lower toe-side leg 2488b. The flexure region 2433 allows the X-shaped pneumatic insert 2440 to flex or deform, thereby promoting the transition between a compressed state and an operative state. Moreover, the flexure region 2433 facilitates the bending, flexing, twisting, or compressing of the legs 2468a, 2468b, 2488a, 2488b about the central portion 2469.

As previously mentioned, the flexure region 2433 of the X-shaped pneumatic insert 2440 allows the legs 2468a, 2468b, 2488a, 2488b to pivot about the central portion 2469. In the operative state, substantially no exterior forces are acting on the arched pneumatic insert 2440, such that the legs 2468a, 2468b, 2488a, 2488b are not pinched or stretched. As such, the operative state defines an operative state width of the X-shaped pneumatic insert 2440, measured from a heel side of the heel region 2463 and a toe side of the toe region 2464 when the X-shaped pneumatic insert 2440 is in the operative state. Alternatively, in the compressed state, the legs 2468a, 2468b, 2488a, 2488b pivot about the central portion 2469, thereby bringing opposing legs 2468a, 2468b, 2488a, 2488b closer together. In some embodiments, the flexure region 2433 is configured to bring the upper heel-side leg 2468a and the upper toe-side leg 2468b closer together and the lower heel-side leg 2488a and the lower toe-side leg 2488b closer together, in the compressed state. Due the substantially symmetrical shape of the X-shaped pneumatic insert 2440, the flexure region 2433 can comprise a rotated orientation. Specifically, in some embodiments, the flexure region 2433 is configured to bring the upper heel-side leg 2468a and the lower heel-side leg 2488a closer together, and the upper toe-side leg 2468b and the lower toe-side leg 2488b closer together, in the compressed configuration. As such, the compressed state defines a compressed state width, measured as the width between the heel side of the heel region 2463 and the toc side of the toe region 2464 or between an upper side of an X-shaped pneumatic insert top region and a lower side of an X-shaped pneumatic insert bottom region when the X-shaped pneumatic insert 2440 is in the compressed state. The operative state width is greater than the compressed state width, due to the pinched configuration of the legs 2468a, 2468b, 2488a, 2488b in the compressed state. The compressed state width defines a constricted overall volume of the X-shaped pneumatic insert 2440, allowing for easy insertion into the cavity 2425. Moreover, the X-shaped pneumatic insert 2440 can comprise similar features to the previously mentioned inserts.

The club head 2400 comprises a plurality of retainers. As illustrated in FIG. 48, the upper heel-side leg 2468a and the upper toe-side leg 2468b each engage the top rail undercut 2430, and the lower heel-side leg 2488a and the lower toe-side leg 2488b each engage the lower interior undercut 2431. Further, the X-shaped pneumatic insert 2440 comprises a rear protrusion 2467 that engages a mass pad top surface 2484. In some embodiments, the X-shaped pneumatic insert 2440 is secured solely by the plurality of retainers. In other embodiments, the X-shaped pneumatic insert 2440 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 2446.

N. Corrugated Pneumatic Insert

FIGS. 49 and 50 illustrate a club head 2500 comprising a corrugated pneumatic insert 2540. The corrugated pneumatic insert 2540 comprises a plurality of corrugations 2587 extending rearward, opposite the insert forward surface 2546. In the illustrated embodiment, the plurality of corrugations can have the same or different lengths (i.e., measured between opposite ends of a given corrugation) and/or the same or different widths (i.e., measured between opposing surfaces of a given corrugation). Referring to FIG. 50, a gap 2585 can be formed between each adjacent corrugation 2587. In some embodiments, the gaps 2585 can have the same or different widths. The gaps 2585 allow the corrugated pneumatic insert 2540 to be folded or deformed during installation, thereby allowing the corrugated pneumatic insert 2540 to be installed through a smaller rear opening 2522. Further, the corrugations 2587 can function as localized dampers or localized reinforcements. The corrugations 2587 can act as insert ribs contacting discrete, localized areas of the club head interior surfaces. In some embodiments, the chamber 2544 extends continuously throughout the corrugated pneumatic insert 2540, and the chamber 2544 can extend through each of the corrugations 2587. In other embodiments, one or more of the corrugations 2587 can be solidly-constructed, such that the corrugation 2587 is filled with solid membrane material. Although the Figures illustrate the corrugations 2587 extending rearward and being formed opposite the insert forward surface 2546, one or more corrugations can be provided on any insert surface and extend in any suitable direction.

The club head 2500 comprises a plurality of retainers. As illustrated in FIG. 50, the insert top end 2561 engages a top rail undercut 2530, and the insert bottom end 2562 engages a lower interior undercut 2531. Further, the corrugations 2587 can form insert retainers. In some embodiments, the club head 2500 can form one or more club head retainers configured to receive one or more corrugations 2587. In the illustrated embodiment, one or more of the corrugations engages an internal mass pad 2580, thereby helping secure the corrugated pneumatic insert 2540. In some embodiments, the corrugated pneumatic insert 2540 is secured solely by the plurality of retainers. In other embodiments, the corrugated pneumatic insert 2540 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 2546.

O. Creased Pneumatic Insert

FIG. 51 illustrates a club head 2600 comprising a creased pneumatic insert 2640. The creased pneumatic insert 2640 comprises a crease 2689 formed into the insert forward surface 2646. The crease 2689 allows the creased pneumatic insert 2640 to be folded or deformed during installation, thereby allowing the creased pneumatic insert 2640 to be installed through a smaller rear opening. The crease 2689 can extend entirely across the insert forward surface in a substantially heel-to-toe direction from the insert heel end 2663 to the insert toe end 2664. In some embodiments, as illustrated in FIG. 51, the crease 2689 can be angled to substantially mirror the shape of the top rail 2610. In this configuration, the pneumatic insert 2640 can fold about the crease 2689 such that the insert top end 2661 can fit underneath the rear opening proximate the top rail 2610. Other embodiments, such as club head 2700 illustrated in FIG. 52, can comprise a crease 2789 that extends in a heel-to-toe direction that is substantially parallel to the sole 2712. Although the crease 2789 is illustrated extending in a substantially heel-to-toe direction, the creased pneumatic insert 2740 can extend in any direction, such as a substantially vertical direction, or a diagonal direction. Further, in some embodiments, the crease 2689 can be curved, arcuate, or comprise any other suitable shape, rather than comprising a substantially linear shape. Further, although the crease 2689 is illustrated as being formed into the insert forward surface 2646, one or more creases 2689 can be formed into any suitable surface of the creased pneumatic insert 2640, including, but not limited to, the insert rear surface 2648.

The club head 2600 comprises a plurality of retainers. As illustrated in FIG. 51, the insert top end 2661 engages a top rail undercut 2630, the insert bottom end 2662 engages a lower interior undercut 2631, and the pneumatic insert 2640 comprises a rear protrusion 2667 that engages a mass pad top surface 2684. Further, the crease 2689 can form an insert retainer. In some embodiments, the club head 2600 can form one or more club head retainers configured to engage the crease 2689. For example, in some embodiments, one or more club head interior surfaces can form a protrusion configured to engage the crease 2689 and secured the creased pneumatic insert 2640. In some embodiments, the creased pneumatic insert 2640 is secured solely by the plurality of retainers. In other embodiments, the creased pneumatic insert 2640 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 2646.

P. Pneumatic Insert with Stiffening Members

In some embodiments, the pneumatic insert can comprise one or more stiffening members. The stiffening members can reinforce the pneumatic insert to control insert deformation during use. The pneumatic insert comprising one or more stiffening members can selectively stiffen portions of the club head, thereby controlling vibration damping and club head flexibility. In some embodiments, one or more stiffening members can be embedded in the membrane. In other embodiments, one or more stiffening members can be formed on an interior surface of the membrane to extend through or occupy a portion of the hollow chamber. In some embodiments, one or more stiffening members can form an insert retainer. The stiffening member can engage one or more club head retainers. In such embodiments, the stiffening member can reinforce the pneumatic insert and prevent pneumatic insert from deforming and disengaging the club head retainer during use.

The one or more stiffeners can be formed of a stiffer material than the membrane material. The stiffener material can be selected based on the desired insert stiffness, desired vibration damping effect, or the desired reinforcing effect. The stiffening member material can comprise sufficient stiffness while comprising a low density to increase discretionary mass. In some embodiments, the stiffener material can be a plastic, a composite, a spring steel, a steel or steel alloy, a titanium or titanium alloy, an aluminum or aluminum alloy, or any other material with a suitable stiffness.

FIGS. 53 and 54 illustrate a club head 2800 with a pneumatic insert 2840 comprising a pair of stiffening members 2890a, 2890b. The pneumatic insert 2840 comprises a heel-side stiffening member 2890a and a toe-side stiffening member 2890b. The stiffening members 2890a, 2890b each extend substantially vertically, from the insert top end 2861 to the insert bottom end 2862. Referring to FIG. 54, the stiffening members 2890a, 2890b are attached to the membrane inner surface 2849 and occupy a portion of the chamber 2844. In the illustrated embodiment, the stiffening members 2890a, 2890b are located only near the insert forward surface 2846 and do not extend through the entire chamber 2844 to near the insert rear surface 2848. This configuration locally stiffens the strike face 2802, allowing the strike face 2802 to be thinned without sacrificing durability. In some embodiments, the stiffening members 2890a, 2890b can be spaced approximately equally from the YZ plane. This configuration provides balanced reinforcement and damping to areas of the strike face 2802 near center. In some embodiments, one or more of the stiffening members can extend in a substantially heel-to-toe direction, a substantially diagonal direction, or in any or suitable orientation. The pneumatic insert 2840 can comprise any number of stiffening members. The pneumatic insert 2840 can comprise one, two, three, four, five, six, seven, eight, nine, ten, or any suitable number of stiffening members.

FIGS. 55 and 56 illustrate a club head 2900 with a pneumatic insert 2940 comprising a central stiffening member 2991. The central stiffening member 2991 substantially vertically, from the insert top end 2961 to the insert bottom end 2962. Referring to FIG. 56, the central stiffening member 2991 extends in a front-to-rear direction through the entire chamber 2944 and contacts the membrane inner surface 2949 proximate both the insert forward surface 2946 and the insert rear surface 2948. The central stiffening member 2991 substantially connects the strike face 2902 to the rear wall, significantly damping vibrations and reinforcing the club head 2900. In some embodiments, the central stiffening member 2991 comprises an aperture 2992 formed through lateral surfaces of the central stiffening member 2991. The aperture 2992 can reduce the central stiffening member mass and increase the flexibility of the central stiffening member 2991. The aperture 2992 can be shaped or sized to control the stiffening effect. A larger aperture 2992 can reduce the stiffness of the central stiffening member 2991, and thereby reduce the overall stiffness of the pneumatic insert 2940. The central stiffening member 2991 can comprise any number of apertures 2992 to control the desired insert stiffness or damping effect. In some embodiments the central stiffening member 2991 can be located on or near the YZ plane. This configuration increases reinforcement and vibration damping to areas of the strike face 2902 near center.

Q. Pneumatic Insert with Slots

FIGS. 57 and 58 illustrate a club head 3100 comprising a pneumatic insert 3140 with one or more slots 3195a, 3195b. The pneumatic insert 3140 comprises an upper insert portion 3158 and a lower insert portion 3165. The upper insert portion 3158 comprises an upper portion bottom wall 3196 and the lower insert portion 3165 comprises a lower portion upper wall 3197. The upper portion lower wall 3196 and the lower portion upper wall 3197 can be at least partially separated by a forward slot 3195a and a rearward slot 3195b. The upper portion lower wall 3196 and the lower portion upper wall 3197 can be connected by a connecting wall 3194. The connecting wall 3194 can be substantially thin and deformable. In some embodiments, the connecting wall 3194 is solid membrane material, and does not form a portion of the chamber. The slots 3195a, 3195b and connecting wall 3194 allow the pneumatic insert 3140 to be folded or deformed during installation, thereby allowing the pneumatic insert 3140 to be installed through a small rear opening.

As illustrated in FIG. 57 and FIG. 58, the upper insert portion 3158 comprises an upper chamber 3159 and the lower insert portion 3165 comprises a lower chamber 3166. The slots 3195a, 3195b extend from the insert toe end 3164 at least partially toward the insert heel end 3163. In some embodiments, the slots 3195a, 3195b terminate short of the insert heel end 3163. In such embodiments, the upper and lower chambers 3159, 3166 can be continuously connected near the insert heel end 3163. In other embodiments, the slots 3195a, 3195b can extend entirely from the insert toe end 3164 to the insert heel end 3163, and the connecting wall 3194 is the only portion of the pneumatic insert 3140 joining the upper insert portion 3158 and the lower insert portion 3165. In such embodiments, the upper chamber 3159 and the lower chamber 3166 can be separate.

In some embodiments, the slots 3195a, 3195b can form insert retainers. In some embodiments, the club head 3100 can form one or more club head retainers configured to engage one or more of the slots 3195a, 3195b. For example, in some embodiments, one or more club head interior surfaces can form a protrusion configured to engage one or more of the slots 3195a, 3195b secure the pneumatic insert 3140. In some embodiments, the pneumatic insert 3140 is secured solely by the retainers. In other embodiments, the pneumatic insert 3140 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 3146.

R. Multi-Chamber Pneumatic Insert with Vertical Connecting Wall

In many embodiments, as best illustrated in FIGS. 71 and 72, pneumatic insert 4640 can comprise multiple chambers 4644A, 4644B. The flexure region 4633 of the pneumatic insert 4640, defined below, promotes the transition between a compressed state and an operative state. The compressed state allows for easy insert insertion into the cavity 4625 and the operative state defines the insertion orientation after the insert is placed within the cavity 4625. Moreover, the pneumatic insert 4640 can comprise similar features to the previously mentioned inserts.

Specifically, the pneumatic insert 4640 can comprise multiple chambers 4644A, 4644B joined by a connecting wall 4694. This configuration improves pneumatic insert flexibility, thereby allowing the pneumatic insert 4640 to be deformed and easily installed within the cavity 4625. Referring to FIGS. 71 and 72, the pneumatic insert 4640 comprises a heel-side membrane 4642A at least partially enclosing a heel-side chamber 4644A and a toe-side membrane 4642B at least partially enclosing a toe-side chamber 4644B. The heel-side membrane 4642A and toe-side membrane 4642B are joined by a connecting wall 4694 extending vertically therebetween. Moreover, the toe-side membrane 4642B comprises a toe-side intermediate wall 4665b and the heel-side membrane 4642A comprises a heel-side intermediate wall 4665a opposite the toe-side intermediate wall 4665b.

In some embodiments, the flexure region 4633 defines the region of the pneumatic insert 4640 between a heel region 4663 and a toe region 4664. The heel region 4663 defines at least a portion of the toe-side membrane 4642B and the toe region 4664 defines at least a portion of the heel-side membrane 4642A. The flexure region further defines the connecting wall 4694, the toe-side intermediate wall 4665b, and the heel-side intermediate wall 4665b. The connecting wall 4694 can be substantially thin and deformable, thereby creating structural discontinuity between the membranes 4642A, 4642B. In some embodiments, the connecting wall 4694 is a thin, solid piece of membrane material, that does not form a portion of either the heel-side chamber 4644A or the toe-side chamber 4644B. In the illustrated embodiment, the connecting wall 4694 is thinner than the surrounding portions of the pneumatic insert 4640, such that one or more slots 4695 are formed between the heel-side membrane 4642A and the toe-side membrane 4642B.

The pneumatic insert 4640 with multiple chambers 4644A, 4644B joined by a connecting wall 4694 improves manufacturing case over a uniformly shaped pneumatic insert by improving the ability to deform the pneumatic insert 4640 during installation. The flexure region 4633 allows the pneumatic insert 4640 to be easily folded along the connecting wall 4694 and installed through a small rear opening. The folding or bending along the flexure region 4633 defines the pneumatic insert 4640 in a compressed state. In other words, in the compressed state, membranes 4642A, 4642B pivot about the connecting wall 4694, thereby shrinking the size of the slot 4695 and bringing the membranes 4642A, 4642B closer together. As such, the compressed state defines an operative state width OS_W, measured from a heel side of the heel-side membrane 4642A and a toe side of the toe-side membrane 4642B, as illustrated in FIG. 73B. Alternatively, in the operative state, substantially no exterior forces are acting on the pneumatic insert 4640, such that the membranes 4642A, 4642B are not twisted, pinched, or stretched. As such, the operative state defines a compressed state width CS_W of the pneumatic insert 4640 measured from a heel side of the heel-side membrane 4642A and a toe side of the toe-side membrane 4642B, as illustrated in FIG. 73A. The operative state width OS_W is less than the compressed state width CS_W, due to the twisted or bent configuration of the membranes 4642A, 4642B in the compressed state. The compressed state width CS_W defines a constricted overall volume of the pneumatic insert 4640, allowing for easy insertion into the cavity 4625.

Although the connecting wall 4694 of the illustrated embodiment extends vertically, other pneumatic insert embodiments with multiple chambers can comprise a connecting wall extending in a substantially horizontal direction or a substantially diagonal direction. Further, although the connecting wall 4694 of the illustrated embodiment extends along the entire juncture between the heel-side membrane 4642A and the toe-side membrane 4642B (i.e., the entire distance between the insert top end 4661 and the insert bottom end 4662), in other embodiments, the connecting wall 4694 can extend only along only a portion of the juncture between the heel-side membrane 4642A and the toe-side membrane 4642B. In such embodiments, an empty void can be formed between portions of the heel-side membrane 4642A and the toe-side membrane 4642B. In other embodiments, the connecting wall 4694 can extend discontinuously and/or intermittently along the juncture between the heel-side membrane 4642A and the toe-side membrane 4642B.

In some embodiments, the connecting wall 4694 can form one or more insert retainers. In some embodiments, the club head 4600 can form one or more club head retainers configured to engage the connecting wall 4694 and/or the slot 4695 formed between the heel-side membrane 4642A and the toe-side membrane 4642B. For example, in some embodiments, one or more club head interior surfaces can form a protrusion configured to engage the connecting wall 4694 to secure the pneumatic insert 4640. In some embodiments, the pneumatic insert 4640 is secured solely by the retainers. In other embodiments, the pneumatic insert 4640 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 4646.

S. Multiple Sub-Chamber Pneumatic Insert with Connecting Ducts

In many embodiments, as best illustrated in FIGS. 73 and 74, pneumatic insert 4740 can comprise a single chamber 4744, divided into one or more sub-chambers 4766A, 4766B. Similar to the pneumatic inserts described above, the flexure region 4733 of the pneumatic insert 4740, defined below, promotes the transition between a compressed state and an operative state. The compressed state allows for easy insert insertion into the cavity 4725 and the operative state defines the insertion orientation after the insert is placed within the cavity 4725. Moreover, the pneumatic insert 4740 can comprise similar features to the previously mentioned inserts.

Specifically, the pneumatic insert 4740 can have a single chamber 4744 divided into one or more sub-chambers 4766A, 4766B connected by one or more connecting ducts 4755. This configuration improves pneumatic insert flexibility, thereby allowing the pneumatic insert 4740 to be deformed and easily installed within the cavity 4725. Referring to FIG. 76, the pneumatic insert 4740 comprises a heel-side membrane 4742A at least partially enclosing a heel-side sub-chamber 4766A and a toe-side membrane 4742B at least partially enclosing a toe-side sub-chamber 4766B. Moreover, the toe-side membrane 4742B comprises a toe-side intermediate wall 4765b and the heel-side membrane 4742A comprises a heel-side intermediate wall 4765a opposite the toe-side intermediate wall 4765b. The heel-side sub-chamber 4766A and toe-side sub-chamber 4766B can be separated by a void 4785 therebetween. The heel-side sub-chamber 4766A and toc-side sub-chamber 4766B are connected by one or more connecting ducts 4755 extending across the void between the heel-side intermediate wall 4765a and the toe-side intermediate wall 4765b.

In some embodiments, the flexure region 4733 defines the region of the pneumatic insert 4740 between a heel region 4763 and a toe region 4764. The heel region 4763 defines at least a portion of the toe-side membrane 4742B and the toe region 4764 defines at least a portion of the heel-side membrane 4742A. The flexure region further defines the one or more connecting ducts 4755, the void 4785, the toe-side intermediate wall 4765b, and the heel-side intermediate wall 4765a. The flexure region 4733 creates structural discontinuity between the heel-side sub-chamber 4766A and toe-side sub-chamber 4766B, thereby promoting bending and twisting of the pneumatic insert 4740.

As illustrated in FIG. 77, the connecting ducts 4755 are hollow, and each provide a passageway 4795 fluidly communicating the heel-side sub-chamber 4766A and toe-side sub-chamber 4766B. As such, the pneumatic insert 4740 forms a singular, continuous chamber 4744. In some embodiments, rather than one or more connecting ducts, the heel side sub-chamber 4766A and toe-side sub-chamber 4766B can be connected by one or more connecting bridges. The connecting bridges can be substantially solid such that there is no passageway between the heel side sub-chamber 4766A and toe-side sub-chamber 4766B.

As mentioned above, the pneumatic insert 4740 with one or more sub-chambers 4766A, 4766B improves manufacturing ease over a uniformly shaped pneumatic insert by improving the ability to deform the pneumatic insert 4740 during installation. The flexible connecting ducts 4755, which are made of membrane material, allow the pneumatic insert 4740 to be easily folded along the void 4785 and installed through a small rear opening.

Furthermore, the folding or bending along the flexure region 4733 defines the pneumatic insert 4740 in a compressed state. In other words, in the compressed state, membranes 4742A, 4742B to pivot or contort about the flexure, thereby shrinking the size of the void 4785 and bringing the membranes 4742A, 4742B closer together. As such, the compressed state defines an operative state width OS_W, measured from a heel side of the heel-side membrane 4742A and a toe side of the toe-side membrane 4742B, as illustrated in FIG. 75. Alternatively, in the operative state, substantially no exterior forces are acting on the pneumatic insert 4740, such that the membranes 4742A, 4742B are not twisted, pinched, or stretched. As such, the operative state defines a compressed state width CS_W of the pneumatic insert 4740 measured from a heel side of the heel-side membrane 4742A and a toe side of the toe-side membrane 4742B. The operative state width OS_W is less than the compressed state width CS_W, due to the twisted or bent configuration of the membranes 4742A, 4742B in the compressed state. The compressed state width CS_W defines a constricted overall volume of the pneumatic insert 4740, allowing for easy insertion into the cavity 4725.

In some embodiments, the connecting ducts 4755 can form insert retainers. In some embodiments, the club head 4700 can form one or more club head retainers configured to engage one or more of the connecting ducts 4755 and/or the void 4785 therebetween. For example, in some embodiments, one or more club head interior surfaces can form a protrusion configured to engage the void 4785 and one or more of the connecting ducts 4755 to secure the pneumatic insert 4740. In some embodiments, the pneumatic insert 4740 is secured solely by the retainers. In other embodiments, the pneumatic insert 4740 is further secured by an additional coupling means, such as a polymer-based tape applied to the insert forward surface 4746.

T. Pneumatic Insert Solid Portions

FIGS. 59A-59B illustrate various embodiments of pneumatic inserts comprising one or more insert solid portions. The one or more insert solid portions can form an insert retainer. The insert solid portions can comprise continuous, solid material, rather than being hollow and filled with pressurized gas. The one or more insert solid portions can engage one or more club head retainers. In some embodiments, any of the insert solid portions described herein can be configured to engage any one or combination of the club head retainers described above. In some embodiments, an insert solid portion can protrude into a club head retainer and be secured therein. In some embodiments, one or more insert solid portions can interlock with a club head retainer. The one or more insert solid portions can provide greater resistance against insert deformation than the hollow portions of the pneumatic insert. The insert solid portions can thereby remain secure within the corresponding club head retainer, even as the club head flexes at impact. In some embodiments, the one or more insert solid portions can be integrally formed with the membrane and can comprise membrane material. In other embodiments, the one or more insert solid portions can be filled with a material other than the membrane material.

FIGS. 59A and 59B illustrate a pneumatic insert 3240 with a top rail insert solid portion 3268a, a sole insert solid portion 3268b, and a rear insert solid portion 3268c. The top rail insert solid portion 3268a is located proximate the insert top end 3261. The top rail insert solid portion 3268a solidly fills an upper portion of the chamber 3244 between the insert forward surface 3246 and the insert rear surface 3248. In some embodiments, when the pneumatic insert 3240 is installed, the top rail insert solid portion 3268a can engage a club head retainer near the top rail. In some embodiments, the top rail insert solid portion 3268a can engage a club head retainer such as a top rail undercut (described in detail above). The sole insert solid portion 3268b is located proximate the insert bottom end 3262. The sole insert solid portion 3268b solidly fills a lower portion of the chamber 3244 between the insert forward surface 3246 and the insert rear surface 3248. In some embodiments, when the pneumatic insert 3240 is installed, the sole insert solid portion 3268b can engage a club head retainer near the sole, such as a lower interior undercut (described in detail above). In some embodiments, the sole insert solid portion 3268b can engage a club head retainer such as a lower interior undercut (described in further detail below). The rear insert solid portion 3268c protrudes into the chamber 3244 from the insert rear surface 3248. In some embodiments, as illustrated in FIG. 59B, the rear insert solid portion 3268c can protrude rearward from the main body of the pneumatic insert 3240. In some embodiments, when the pneumatic insert 3240 is installed, the rear insert solid portion 3268c can engage a club head retainer near the rear wall. In some embodiments, the rear insert solid portion 3268c can engage a club head retainer formed by a mass pad (described in detail above).

The pneumatic insert 3240 can comprise a top rail insert solid portion 3268a, a sole insert solid portion 3268b, a rear insert solid portion 3268c, or any combination thereof. For example, FIGS. 60A and 60B illustrate an embodiment of a pneumatic insert 3340 comprising only a rear insert solid portion 3368c, FIGS. 61A and 61B illustrate an embodiment of a pneumatic insert 3440 comprising only a top rail insert solid portion 3468a, and FIGS. 62A and 62B illustrate an embodiment of a pneumatic insert 3540 comprising only a sole insert solid portion 3568b. In other embodiments, one or more insert solid portions can be located in any portion of the pneumatic insert.

U. Insert Ribs

In some embodiments, as illustrated in FIGS. 63A-63D, the pneumatic insert can comprise one or more insert ribs. The insert ribs can locally damp or reinforce one or more club head interior surfaces. The insert ribs can be integrally formed with the membrane and can comprise membrane material. In other embodiments, the insert ribs can be separately formed from the membrane and attached thereto. In some embodiments the insert ribs can function as an insert retainer. In some embodiments, the club head can comprise one or more club head retainers, such as a groove or slot formed into one or more of the club head interior surfaces. One or more insert ribs can be configured to engage said club head retainers, thereby securing the pneumatic insert within the cavity. The configuration and number of insert ribs is not limited to those of the illustrated embodiments described below. In some embodiments, the pneumatic insert can comprise any number of insert ribs. In some embodiments, the pneumatic insert can comprise one, two, three, four, five, six, seven, eight, nine, ten, or any suitable number of insert ribs. One or more insert ribs can be applied to any of the pneumatic insert embodiments described herein.

FIG. 63A illustrates a pneumatic insert 3640 comprising a plurality of horizontal insert ribs 3638. The insert ribs 3638 extend substantially between the insert heel end 3663 and the insert toe end 3664. The insert ribs 3638 can protrude outward from the membrane outer surface 3647. In the illustrated embodiment of FIG. 63A, the insert ribs 3638 are located on the insert forward surface 3646. In other embodiments, one or more insert ribs 3638 can be located on any portion of the pneumatic insert 3640 including, but not limited to, the insert top end 3661, the insert bottom end 3662, the insert heel end 3663, the insert toe end 3664, the insert forward surface 3646, or the insert rear surface 3648.

FIG. 63B illustrates a pneumatic insert 3740 comprising a plurality of diagonal insert ribs 3738. The insert ribs 3738 can be substantially similar to insert ribs 3638, but for the differing directionality. As illustrated, each insert rib 3738 extends in a direction from near the insert toe end 3764 and insert bottom end 3762 to near the insert heel end 3763 and insert top end 3761. In other embodiments, the diagonal insert ribs 3738 can extend in the opposite direction (i.e. from near the insert toe end 3764 and insert top end 3761 to near the insert heel end 3763 and insert bottom end 3762).

FIG. 63C illustrates a pneumatic insert 3840 comprising a plurality of vertical insert ribs 3838. The insert ribs 3838 can be substantially similar to insert ribs 3638, but for the differing directionality. The insert ribs 3838 can extend substantially between the insert top end 3861 and the insert bottom end 3862.

FIG. 63D illustrates a pneumatic insert 3940 comprising a plurality of vertical insert ribs 3938 that form a central pattern. The insert ribs 3938 can comprise a central insert rib 3938a located substantially equidistant between the insert heel end 3963 and the insert toe end 3964. Each successive insert rib 3938 in the pattern moving away from the central insert rib 3938a can be shorter than the insert ribs 3938 nearer the central insert rib 3938a. Accordingly, the insert ribs 3938 collective form a circular or ovular pattern that can be centered approximately around the center of the insert forward surface 3946. In some embodiments, when the pneumatic insert 3940 is installed, the insert rib pattern can be configured to correspond with the strike face center location. As such, the insert ribs 3938 can locally damp or reinforce the area of the strike face near center, which typically experiences high vibration and flexure.

V. Pneumatic Insert with Weight Members

In some embodiments, the pneumatic insert can comprise one or more weight members. The one or more weight members can concentrate discretionary mass to create a desirable club head mass distribution. In some embodiments, one or more weight members can be enclosed by the membrane and occupy a portion of the chamber. In some embodiments, one or more weight members can be attached to the membrane outer surface or can form an outer surface of the pneumatic insert. In some embodiments, one or more weight members can be embedded in the membrane. One or more insert ribs can be applied to any of the pneumatic insert embodiments described herein.

The one or more weight members can be formed of a material having a greater density than the membrane material and/or the club head body material. In some embodiments, the one or more weight members can be formed from a material such as a metallic alloy comprising a tungsten alloy, a tungsten-nickel alloy, and/or a copper alloy.

In some embodiments, the one or more weight members can comprise a mass between 2 and 50 grams. In some embodiments, one or more weight members can comprise a mass greater than 2 grams, greater than 5 grams, greater than 10 grams, greater than 15 grams, greater than 20 grams, greater than 25 grams, greater than 30 grams, greater than 35 grams, greater than 40 grams, greater than 45 grams, or greater than 50 grams.

FIG. 64 illustrates a pneumatic insert 4140 comprising a plurality of weight members 4199a, 4199b. The pneumatic insert 4140 comprises a heel-side weight member 4199a and a toe-side weight member 4199b. The membrane 4142 encloses the weight members 4199a, 4199b within the chamber of the pneumatic insert 4140. Both weight members 4199a, 4199b can be located towards the insert bottom end 4162. This configuration concentrates mass near the sole and lowers the club head CG. In the illustrated embodiment, the heel-side weight member 4199a is located proximate the insert heel end 4163 and the toe-side weight member 4199b is located proximate the insert toe end 4164. This configuration contributes to club head perimeter weighting and increases MOI. In other embodiments, the pneumatic insert 4140 can comprise any other suitable configuration of weight members. In some embodiments, one or more weight members can be located in any portion of the pneumatic insert 4140, such as near the insert top end 4161, the insert bottom end 4162, the insert heel end 4163, the insert toe end 4164, the insert forward surface 4146, the insert rear surface 4148, or any combination thereof. In some embodiments, rather than comprising two weight members 4199a, 4199b, the pneumatic insert 4140 can comprise a single weight member, or any other suitable number of weight members.

IV. Mass Properties of Club Head Comprising Pneumatic Insert

Described above, the pneumatic inserts and retainers described herein create a lightweight damping system that creates discretionary mass over the prior art club heads that include solidly constructed inserts or robust insert retaining features. This discretionary mass can be used to provide a desirable mass distribution and improve mass properties. As described below, the club head can comprise high MOI values and/or low and rearward CG positions that improve ball flight performance.

In some embodiments, the club head comprises an I_XX between 500 g*cm² and 2000 g*cm². In some embodiments, the I_XX can be between 500 and 800 g*cm², 800 and 1100 g*cm², 1100 and 1400 g*cm², 1400 and 1700 g*cm², or between 1700 and 2000 g*cm². In some embodiments, the I_XX can be greater than 500 g*cm², 600 g*cm², 700 g*cm², 800 g*cm², 900 g*cm², 1000 g*cm², 1100 g*cm², 1200 g*cm², 1300 g*cm², 1400 g*cm², 1500 g*cm², 1600 g*cm², 1700 g*cm², 1800 g*cm², or greater than 1900 g*cm².

In some embodiments, the club head comprises an I_YY between 2000 g*cm² and 4000 g*cm². In some embodiments, the I_YY can be between 2000 and 2250 g*cm², 2250 g*cm² and 2500 g*cm², 2500 and 2750 g*cm², 2750 and 3000 g*cm², 3000 and 3250 g*cm², 3250 and 3500 g*cm², 3500 and 3750 g*cm², or between 3750 and 4000 g*cm². In some embodiments, the Ivy can be greater than 2000 g*cm², 2100 g*cm², 2200 g*cm², 2300 g*cm², 2400 g*cm², 2500 g*cm², 2600 g*cm², 2700 g*cm², 2800 g*cm², 2900 g*cm², 3000 g*cm², 3100 g*cm², 3200 g*cm², 3300 g*cm², 3400 g*cm², 3500 g*cm², 3600 g*cm², 3700 g*cm², 3800 g*cm², or greater than 3900 g*cm².

In some embodiments, the club head comprises an I_ZZ between 2000 g*cm² and 4000 g*cm². In some embodiments, the I_ZZ can be between 2000 and 2250 g*cm², 2250 g*cm² and 2500 g*cm², 2500 and 2750 g*cm², 2750 and 3000 g*cm², 3000 and 3250 g*cm², 3250 and 3500 g*cm², 3500 and 3750 g*cm², or between 3750 and 4000 g*cm². In some embodiments, the Iyy can be greater than 2000 g*cm², 2100 g*cm², 2200 g*cm², 2300 g*cm², 2400 g*cm², 2500 g*cm², 2600 g*cm², 2700 g*cm², 2800 g*cm², 2900 g*cm², 3000 g*cm², 3100 g*cm², 3200 g*cm², 3300 g*cm², 3400 g*cm², 3500 g*cm², 3600 g*cm², 3700 g*cm², 3800 g*cm², or greater than 3900 g*cm².

The CG_Y location of the club head can be between 0.00 and −0.25 inch. In some embodiments, the CG_Y location can be between −0.10 and −0.15 inch, between −0.15 and −0.20 inch, or between −0.20 and −0.25 inch. In some embodiments, the CG_Y location can be less than −0.10 inch, less than −0.12 inch, less than −0.14 inch, less than −0.16 inch, less than −0.18 inch, less than −0.20 inch, less than −0.22 inch, less than −0.24 inch, or less than −0.25 inch

The CG_Z location of the iron-type club head can be between −0.20 and 0.15 inch. In some embodiments, the CG_Z location can be between −0.15 and −0.13 inch, between −0.13 and −0.11 inch, between −0.11 and −0.09 inch, between −0.09 and −0.07 inch, or between −0.07 and −0.05 inch. In some embodiments, the CG_Z location can be greater than −0.15 inch, less than −0.13 inch, less than −0.11 inch, less than −0.09 inch, less than −0.07 inch, or less than −0.05 inch.

EXAMPLES

V. Example 1—Sound, Feel, and Ball Flight Performance of Club Head Comprising a Pneumatic Insert

Various performance, sound, and feel characteristics were tested and compared between an exemplary club head comprising a pneumatic insert and a control club head. The exemplary club head was substantially similar to club head 300. In particular, the exemplary club head was a capped hollow-body club head comprising a rear wall partially extending upward from the sole, but not fully to the top rail, to define a rear opening. A pneumatic insert occupied the cavity. A badge covered the rear opening, enclosing the pneumatic insert within the interior cavity.

The control club head was similar to the exemplary club head, but for differences in the damping structures. Rather than a pneumatic insert, a badge was applied directly to the control club head strike face rear surface. Rather than an enclosed interior cavity, the control club head comprised an open cavity that was exposed to the club head exterior, wherein the badge resided within the open cavity. The exemplary pneumatic insert created 5.5 grams of discretionary mass over the control club head, which required a heavier badge to damp vibrations.

A plurality of players hit a representative sample of golf shots with both the exemplary club head and the control club head. All participants then qualitatively rated each club's sound and feel on a scale of “undesirable,” to “desirable,” as outlined in Table 1 below.

TABLE 1
Qualitative Sound and Feel Ratings

Sound

Feel

	Exemplary	Control	Exemplary	Control
Player Response	Club	Club	Club	Club

Undesirable	2	1	1	0
Moderately Undesirable	2	4	1	1
Slightly Undesirable	4	7	2	8
Slightly Desirable	1	3	4	1
Moderately Desirable	9	4	10	9
Desirable	2	1	2	1
Total “undesirable”	8	12	4	9
results
Total “desirable”	12	8	16	11
results

As shown in Table 1, participants, on average, preferred the sound generated at impact by the exemplary club head comprising a pneumatic insert. Specifically, 60% of players described the exemplary club head sound as “moderately desirable,” “slightly desirable,” or “desirable.” In comparison, only 40% of participants described the control club head sound as “moderately desirable,” “slightly desirable,” or “desirable.” Further, 50% more participants (12 compared to 8) positively rated the exemplary club head sound than positively rated the control club head sound. This illustrates a strong preference for the exemplary club head comprising a pneumatic insert.

Similarly, as shown in Table 1, participants generally preferred the feel of the exemplary club head. Specifically, 80% of participants described the exemplary club head feel as “moderately desirable,” “slightly desirable,” or “desirable.” In comparison, only 55% of participants described the control club head feel s “moderately desirable,” “slightly desirable,” or “desirable.” Further, 45% more players (16 compared to 11) positively rated the exemplary club head feel than positively rated the control club head feel. This illustrates a strong preference for the exemplary club head comprising a pneumatic insert.

The results exhibited by Table 1 illustrate the effectiveness of the pneumatic insert in damping impact vibrations in comparison to a club head comprising a prior-art badge. The vibration damping effects of the pneumatic provide a more desirable sound and feel. The results illustrate that a significant number of players prefer the sound and feel of the exemplary club head comprising a pneumatic insert over a control club head comprising a traditional, prior-art badge.

Further, the ball flight performance characteristics of the exemplary club head and the control club head were tested and compared. From the representative sample of shots with both the exemplary club head and the control club head, a variety of ball flight characteristics were recorded. The average ball flight characteristics for both the exemplary club head and the control club head are presented in Table 2 below.

TABLE 2
Ball flight performance data for exemplary club vs. control club

			Carry	Offline
	Ball Speed	Spin Rate	Distance	Distance
	(mph)	(rpm)	(yards)	(yards)

Exemplary Club	122.0	6256	173.4	1.2
Control Club	122.6	6047	174.9	1.3
Percent	0.49	3.39	0.86	8.0
Difference (%)

Table 2 provides average ball flight data for the ball speed, spin rate, carry distance, and offline distance of each club head. Overall, the exemplary club head and the control club head performed comparably. The exemplary club head and the control club head generated ball speeds of 122.0 mph and 122.6 mph, respectively (a negligible 0.49% difference). The exemplary club head exhibited a spin rate of 6256 rpm, while the control club head exhibited a spin rate of 6047 rpm. Therefore, the exemplary club head comprising a pneumatic insert had a spin rate, on average, that was 3.39% greater than the average spin rate of the control club head lacking a pneumatic insert. Further, the exemplary club head displayed an average carry distance of 173.4 yards, while the control club head displayed an average carry distance of 174.9 yards, (a 0.86% difference). Table 2 further illustrates that the percent difference in carry distance between the exemplary club head and the control club head was less than 1.0%, indicating similar performance. Further still, the exemplary club head displayed an average offline distance of 1.2 yards, while the control club head displayed an average offline distance of 1.3 yards. The difference in average offline position between club heads was therefore only 0.1 yards, a negligible value. As such, the ball speed, spin rate, carry distance, and offline distance for each club were all similar for both the exemplary club head comprising a pneumatic insert and the standard club head lacking a pneumatic insert (and comprising a prior-art badge). The results of Tables 1 and 2 illustrate that the pneumatic insert improves club head sound and feel, in comparison to the control club head, without sacrificing performance.

VI. Example 2—Sound and Feel Comparison Between Club Heads Comprising Pneumatic Inserts and Club Head with Injectable Filler Material

The sound and feel were tested and compared between a first and second exemplary club head comprising a pneumatic insert and a valve and a control club head comprising an injectable filler material. The exemplary club heads and the control club head were each capped hollow-body club heads similar to club head 300. Each club head included a rear wall partially extending upward from the sole, but not fully to the top rail, to define a rear opening. The rear opening of each club head was covered by a badge, thereby enclosing an interior cavity. Further, each club head included a strut spanning the rear opening.

The first and second exemplary club heads each comprised a pneumatic insert occupying the interior cavity and were devoid of any filler material other than the pneumatic insert. The first exemplary club head comprised a pneumatic insert having a “duckbill” type valve (as described above) on the insert rear surface, whereas the second exemplary club head comprised a “dome” type valve (as described above). The first and second exemplary club head inserts were substantially similar, other than the valve types.

As discussed above, the control club head was similar to the exemplary club heads, but for the control club head comprising an injectable filler within the interior cavity, rather than a pneumatic insert. Four grams of said injectable filler material was applied to the back of the control club head strike face via the rear opening.

A plurality of players hit a representative sample of golf shots with both the exemplary club heads and the control club head. The players then qualitatively rated each club's sound and feel on a scale of “undesirable,” to “desirable,” as outlined further in Table 3 and Table 4, respectively, below.

TABLE 3
Player feedback on sound for exemplary club vs. control club

Sound

		First	Second
		Exemplary	Exemplary	Control
	Player Response	Club	Club	Club

	Undesirable	0	0	4
	Moderately Undesirable	1	1	1
	Slightly Undesirable	2	1	5
	Slightly Desirable	6	3	5
	Moderately Desirable	9	12	7
	Desirable	2	3	2
	Total “undesirable”	3	2	6
	results
	Total “desirable”	17	18	14
	results

As shown above, players, on average, preferred the sound generated at impact by the exemplary club heads over the control club head. Specifically, 85% of players gave the first exemplary club head sound a positive rating (i.e., “moderately desirable,” “slightly desirable,” or “desirable”), and 90% players gave the second exemplary club head a positive rating. In contrast, 70% of players gave the control club head a positive rating. Therefore, more players preferred the sound generated by the first and second exemplary club heads over the control club head.

TABLE 4
Player feedback on feel for exemplary club vs. control club

Feel

		First	Second
		Exemplary	Exemplary	Control
	Player Response	Club	Club	Club

	Undesirable	0	0	2
	Moderately	0	0	1
	Undesirable
	Slightly Undesirable	3	1	2
	Slightly Desirable	5	4	6
	Moderately Desirable	9	13	7
	Desirable	3	2	2
	Total “undesirable”	3	1	5
	results
	Total “desirable”	17	19	15
	results

As shown above, the players generally preferred the feel generated at impact by the exemplary club heads over the control club head. Specifically, 85% of players positively rated the first exemplary club head feel, and 95% of players positively rated the second exemplary club head. In contrast, only 75% of players positively rated the control club head.

The results exhibited in Tables 3 and 4 illustrate the damping capabilities the pneumatic insert. The results illustrate that, all else equal, the sound and feel of the exemplary club heads comprising a pneumatic insert are both preferred over the sound and feel of a club head comprising a prior art damping means (i.e., an injectable filler material). Further, the results illustrate that the sound and feel improvements are not hampered by pneumatic insert including a valve. Both the “duckbill” and “dome” type valves are viable options that can allow the pneumatic insert to be reinflated without diminishing the damping effect.

VII. Example 3—Ball Flight Performance Comparison Between Club Head Comprising a Pneumatic Insert and Club Head with Injectable Filler Material

The ball flight performance characteristics of an exemplary club head comprising a pneumatic insert were tested and compared to a control club head. The exemplary club head was a capped hollow-body club head substantially similar to club head 300. In particular, the exemplary club head comprised a rear wall partially extending upward from the sole but not fully to the top rail, thereby defining a rear opening. A pneumatic insert occupied the cavity, comprising an insert pressure of approximately 1.0 psi and an insert mass of 4.5 grams. A badge covered the rear opening, enclosing the pneumatic insert within an interior cavity. Further, the exemplary club head included a strut spanning the rear opening.

The control club head was similar to the exemplary club head, but for the control club head lacking a pneumatic insert. Instead, the control club head comprised an injectable filler material within the interior cavity. Five grams of said injectable filler material was applied to the back of the control club head strike face via the rear opening.

A plurality of players hit a representative sample of golf shots with both the exemplary club head and the control club head. The ball flight characteristics of each shot were recorded. The average ball flight data of the test is presented in Table 5 below.

TABLE 5
Ball flight performance data for exemplary club vs. control club

	Ball Speed	Launch Angle	Spin Rate
	(mph)	(°)	(rpm)

	Exemplary Club	122.5	15.0	6205
	Control Club	122.5	14.8	6137
	Percent	0	1.3	1.1
	Difference (%)

Overall, the exemplary club head and the control club head performed comparably, with the exemplary club head exhibiting slight improvements in launch angle and spin rate. The exemplary club head and the control club head generated identical ball speeds (122.5 mph). The exemplary club head exhibited a 15.0° launch angle, while the control club head exhibited a 14.8° launch angle (a 1.3% difference). The exemplary club head exhibited a spin rate of 6205 rpm, while the control club head exhibited a spin rate of 6137 rpm (a 1.1% difference).

The results illustrate that replacing the injectable filler material commonly found in the prior art with a pneumatic insert leads to slight improvements in performance (with the combination of higher launch and higher spin being desirable over a lower launch and lower spin). As discussed above in Example 2, the pneumatic insert improves sound and feel over a similar club head comprising an injectable filler material. Further, the hollow nature of the pneumatic insert provided 0.5 grams of discretionary mass that could be used to further improve ball flight performance. the pneumatic insert. The present example illustrates that the club head comprising a pneumatic insert damps vibrations and improves sound and feel, all without sacrificing ball flight performance.

VIII. Example 4—Modal Frequency Analysis of Club Head Comprising a Pneumatic Insert

The vibrational responses of a first and second exemplary club head each comprising a pneumatic insert were compared to the vibrational response of a control club head via modal analysis. The exemplary club heads and the control club head were each capped hollow-body club heads, similar to club head 300. Each club head included a rear wall partially extending upward from the sole, but not fully to the top rail, to define a rear opening. The rear opening of each club head was covered by a badge, thereby enclosing an interior cavity. The first and second exemplary club heads each comprised a pneumatic insert occupying the interior cavity. The first exemplary club head comprised an insert pressure equal to ambient pressure, while the second exemplary club head comprised an insert pressure of 1 psi. The control club head was substantially similar to the exemplary club heads, but for the control club head lacking a pneumatic insert. The control club head interior cavity was left unoccupied.

All three club heads exhibited a dominant vibrational mode located proximate the center of the strike face rear surface. The control club head exhibited a dominant frequency of 6444 Hz at said vibrational mode. The first exemplary club head exhibited a dominant frequency of 6640 Hz at said vibrational mode. The second exemplary club head exhibited a dominant frequency of 6743 Hz at said vibrational mode. The increase in the dominant frequency between the control club head and the exemplary club heads correlates to a more acoustically pleasing high-pitched sound at impact, rather than a low, dull sound. The comparison illustrates that the inclusion of the pneumatic insert improves the club head vibrational response.

Replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are stated in such claim.

Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.

IX. Example 5—Manufacturability Comparison Between Pneumatic Inserts Comprising a Pinched Column and Pneumatic Inserts Devoid of a Pinched Column

The efficiency of pneumatic insert installation in golf club heads was investigated by comparing the exemplary pneumatic inserts comprising a pinched column as described above versus control pneumatic inserts with a uniform design devoid a pinched column. It is advantageous to manufacture the pneumatic inserts to tight dimensional tolerances so that they more reliably fit within the intended space inside the golf club head. The control pneumatic inserts have a tendency to excessively expand when over pressurized, which renders them too large to fit within the cavity of a golf club head.

To measure installation consistency, a sample of exemplary pneumatic inserts, each comprising a pinched column, and a sample of control pneumatic inserts, each devoid of a pinched column, were fabricated and analyzed according to the same engineering tolerances. Both samples of pneumatic inserts were assigned to four size categories corresponding to types of golf clubs configured to house the pneumatic insert: long irons, mid-sized irons, short irons, and wedges. In this study, long irons included 4 irons and 5 irons; mid-sized irons included 6 irons and 7 irons; short irons included 8 irons and 9 irons; wedges include pitching wedges and utility wedges. For each size category, a yield percentage was determined for the exemplary pneumatic inserts and the control pneumatic inserts. The yield percentage was calculated as the percentage of fabricated pneumatic inserts comprising heights within the engineering tolerances. If a pneumatic insert comprises a height within said engineering tolerances, then it can also fit within the cavity of golf club head. The yield percentages of each sample are summarized in Table 6 below.

TABLE 6
Yield percentage comparison between exemplary pneumatic
inserts and control pneumatic inserts

Yield Percentage

	Control Pneumatic	Exemplary
	Inserts	Pneumatic Inserts
Size Category	(No Pinched Column)	(Pinched Column)
Long Irons	97%	96%
Mid-sized Irons	97%	100%
Short Irons	95%	98%
Wedges	90%	97%

The exemplary pneumatic inserts configured for mid-sized irons, short irons, and wedges comprised higher yield percentages than the control pneumatic inserts. With respect to the pneumatic inserts for mid-sized irons, the exemplary pneumatic inserts exhibited a 3% increase in yield percentage over the control pneumatic inserts. With respect to the pneumatic inserts for short irons, the exemplary pneumatic inserts also exhibited a 3% increase in yield percentage over the control pneumatic inserts. With respect to the pneumatic inserts for wedges, the exemplary pneumatic inserts exhibited a 7% increase in yield percentage over the control pneumatic inserts. Although the yield percentage decreased between the exemplary pneumatic inserts and control pneumatic inserts when configured for long irons, the yield percentage only decreased by 1% from 97% to 96%, a negligible amount. In general, the exemplary pneumatic inserts were more likely to fall within the engineering tolerances when compared to the control pneumatic inserts.

In the same experiment, the process capability index (Cpk) was calculated for the control pneumatic inserts and the exemplary pneumatic inserts across the four size categories. A higher Cpk value is indicative of a process that produces fewer defects. The measurement of Cpk assumes that the pneumatic insert heights are normally distributed and is calculated as a scaled quantity of standard deviations between the mean pneumatic insert manufactured height and the upper and lower engineering tolerances. The exemplary pneumatic inserts comprising a pinched column exhibited an increased Cpk value throughout the long irons, mid-sized irons, short irons, and wedges compared to the control pneumatic inserts. Between two processes, any Cpk increase above zero is emblematic of a more consistent process. The Cpk increase amounts between the exemplary pneumatic inserts and control pneumatic inserts, calculated as the Cpk for the exemplary pneumatic inserts minus the Cpk for the control pneumatic inserts, are outlined in Table 7.

TABLE 7
Cpk Increases between the exemplary pneumatic
inserts and control pneumatic inserts

		Increases in Cpk between the Control
		Pneumatic Inserts and the Exemplary
	Size Category	Pneumatic Inserts
	Long Irons	1.72
	Mid-sized Irons	0.16
	Short Irons	0.26
	Wedges	0.54

With respect to the pneumatic inserts for long irons, the exemplary pneumatic inserts exhibited a Cpk increase of 1.72 over the control pneumatic inserts. With respect to the pneumatic inserts for mid-sized irons, the exemplary pneumatic inserts exhibited a Cpk increase of 0.16 over the control pneumatic inserts. With respect to the pneumatic inserts for short irons, the exemplary pneumatic inserts exhibited a Cpk increase of 0.26 over the control pneumatic inserts. With respect to the pneumatic inserts for wedges, the exemplary pneumatic inserts exhibited a Cpk increase of 0.54 over the control pneumatic inserts. In general, the exemplary pneumatic inserts increased Cpk and enhanced manufacturability when compared to the control pneumatic inserts.

Due to variability in the inflation process, it is advantageous for the pneumatic inserts to maintain a constant height when inflated to different pressures. Another comparison was made between the exemplary pneumatic inserts and the control pneumatic inserts to characterize their respective pressure sensitivities. Specifically, the control pneumatic inserts and the exemplary pneumatic inserts were inflated to different pressure levels to observe the increase in height or “ballooning” effect upon overinflation. The control pneumatic inserts comprise an ideal height of 0.42 inches, while exemplary pneumatic inserts comprise an ideal height of 0.27 inches. When inflated to 1.5 psi, the height of the control pneumatic inserts increased to 0.76 inches, an 81% increase in height from the ideal height of the control pneumatic inserts. Meanwhile, the exemplary pneumatic inserts could be inflated to 1.74 psi and only grow 0.013 inches in height to 0.283 inches, a 4.8% increase. Therefore, the exemplary pneumatic inserts maintained a more constant height when over pressurized than the control pneumatic inserts. The tendency of the control pneumatic inserts to increase in height when over pressurized further explains their lower yield percentage and decreased Cpk in the manufacturing process as outlined in Table 6 and Table 7 above.

The pinched column design present in the exemplary pneumatic inserts improves manufacturing consistency by controlling inflation and maintaining structural integrity under pressure. Furthermore, pneumatic inserts devoid of a pinched column were more sensitive to pressure, and some would overinflate during the manufacturing process. This overinflation led to pneumatic inserts falling outside of the engineering tolerances and thus lower yield percentages.

CLAUSES

Clause 1. An iron-type golf club head, comprising: a body comprising: a front end defining a strike face, a top rail, a sole opposite the top rail, a toe opposite the heel; a rear end opposite the front end, the rear end defining a rear wall extending partially between the sole and the top rail; a cavity at least partially bounded by the strike face, the top rail, the sole, the heel, the toe, and the rear wall; a pneumatic insert disposed in the cavity, the pneumatic insert defining a compressed state and an operative state and further comprising: a membrane enclosing a hollow chamber filled with a pressurized gas; a toe-side region; a heel-side region opposite the toe-side region; a flexure region disposed between and flexibly coupling the toe-side region and the heel-side region; a maximum width measured between a heel side and a toe side of the pneumatic insert; wherein: in the compressed state, the maximum width is shorter than the maximum width in the operative state.

Clause 2. The iron-type golf club head of clause 1, wherein the pneumatic insert further comprises: a heel-side leg disposed in the heel-side region and defining a heel-side free end, a toe-side leg disposed in the toe-side region and defining a toe-side free end, a void disposed in the flexure region and between the heel-side leg and the toe-side leg, a central aperture disposed in the flexure region opposite the heel-side free end and the toe-side free end and fluidly communicating with the void; wherein: the central aperture and the void cooperate to form a keyhole shape.

Clause 3. The iron-type golf club head of clause 2, wherein a web extends across the central aperture and the void.

Clause 4. The iron-type golf club head of clause 2, wherein: the toe-side leg comprises a toe-side intermediate wall, the heel-side leg comprises a heel-side intermediate wall, the central aperture defines a penannular wall between the heel-side intermediate wall and the toe-side intermediate wall, and the keyhole is defined along the penannular wall, the heel-side intermediate wall, and the toe-side intermediate wall.

Clause 5. The iron-type golf club head of clause 2, wherein the pneumatic insert further comprises: a central aperture width, measured along a horizontal plane between opposing ends of the central aperture, of 0.20 inch to 1.00 inch; a void width, measured as the shortest distance between the heel-side leg and the toe-side leg, less than the central aperture width and between 0.125 inch and 0.75 inch.

Clause 6. The iron-type golf club head of clause 1, wherein the membrane further comprises: a heel-side membrane, disposed in the heel-side region, defining a heel-side intermediate wall and at least partially enclosing a heel-side sub-chamber, a toe-side membrane, disposed in the toe-side region, defining a toe-side intermediate wall and at least partially enclosing a toe-side sub-chamber; wherein: the heel-side sub-chamber and toe-side the sub-chamber are separated by the void, the heel-side sub chamber and the toe-side sub-chamber are connected by a connecting duct extending between the heel-side intermediate wall and the toe-side intermediate wall and disposed within the flexure region; the flexure region is defined along the one or more connecting ducts, the void, the toe-side intermediate wall, and the heel-side intermediate wall.

Clause 7. The iron-type golf club head of clause 1, wherein the membrane further comprises: a heel-side membrane, disposed in the heel-side region, defining a heel-side intermediate wall and at least partially enclosing a heel-side chamber, a toe-side membrane, disposed in the toe-side region, defining a toe-side intermediate wall and at least partially enclosing a toe-side chamber, a connecting wall disposed in the flexure region and extending between the heel-side membrane and the toe-side membrane.

Clause 8. The iron-type golf club head of clause 7, wherein the connecting wall comprises a thin, solid section of the membrane that is independent of the heel-side chamber or the toe-side chamber.

Clause 9. The iron-type golf club head of clause 1, wherein the flexure region comprises a structural discontinuity of the pneumatic insert.

Clause 10. The iron-type golf club head of clause 1, wherein the pneumatic insert is secured within the cavity without any adhesives or separate coupling members.

Clause 11. The iron-type golf club head of clause 1, wherein the pneumatic insert is inflated to an insert pressure of between 0 and 5 psi.

Clause 12. The iron-type golf club head of clause 1, wherein the pneumatic insert is inflated to an insert pressure of between 0.5 and 1.5 psi.

Clause 13. The iron-type golf club head of clause 1, wherein the membrane is formed by a process selected from the group consisting of thermoforming, vacuum forming, pressure forming, mechanical forming, drape forming, matched mold forming, twin sheet forming, and billow forming.

Clause 14. An iron-type golf club head, comprising: a body comprising: a front end defining a strike face, a top rail, a sole opposite the top rail, a heel, and a toe opposite the heel; a rear end opposite the front end, the rear end defining a rear wall; a cavity at least partially bounded by the strike face, the top rail, the sole, the heel, the toe, and the rear wall, wherein the rear wall extends partially between the sole and the top rail; a pneumatic insert disposed in the cavity, the pneumatic insert defines a compressed state and an operative state and further comprising: a membrane enclosing a hollow chamber filled with a pressurized gas; a toe-side region; a heel-side region opposite the toe-side region; a flexure region disposed between and flexibly coupling the toe-side region and the heel-side region, defining a section of the pneumatic insert that facilitates the transition between the operative state and the compressed state, and wherein: at least one maximum dimension of the pneumatic insert is greater in the operative state than in the compressed state.

Clause 15. The iron-type golf club head of clause 14, wherein the pneumatic insert further comprises: a heel-side leg disposed in the heel-side region and defining a heel-side free end, a toe-side leg disposed in the toe-side region and defining a toe-side free end, a void disposed in the flexure region and between the heel-side leg and the toe-side leg, a central aperture disposed in the flexure region opposite the heel-side free end and the toe-side free end and fluidly communicating with the void; wherein: the central aperture and the void cooperate to form a keyhole shape.

Clause 16. The iron-type golf club head of clause 15, wherein a web extends across the central aperture and the void.

Clause 17. The iron-type golf club head of clause 15, wherein: the toe-side leg comprises a toe-side intermediate wall, the heel-side leg comprises a heel-side intermediate wall, the central aperture defines a penannular wall between the heel-side intermediate wall and the toe-side intermediate wall, and the keyhole is defined along the penannular wall, the heel-side intermediate wall, and the toe-side intermediate wall.

Clause 18. The iron-type golf club head of clause 15, wherein the pneumatic insert further comprises: a central aperture width, measured along a horizontal plane between opposing ends of the central aperture, of 0.20 inch to 1.00 inch; a void width, measured as the shortest distance between the heel-side leg and the toe-side leg, less than the central aperture width and between 0.125 inch and 0.75 inch.

Clause 19. The iron-type golf club head of clause 14, wherein the membrane further comprises: a heel-side membrane, disposed in the heel-side region, defining a heel-side intermediate wall and at least partially enclosing a heel-side sub-chamber, a toe-side membrane, disposed in the toe-side region, defining a toe-side intermediate wall and at least partially enclosing a toe-side sub-chamber; wherein: the heel-side sub-chamber and toe-side the sub-chamber are separated by the void, the heel-side sub chamber and the toe-side sub-chamber are connected by a connecting duct extending between the heel-side intermediate wall and the toe-side intermediate wall and disposed within the flexure region; the flexure region is defined along the one or more connecting ducts, the void, the toe-side intermediate wall, and the heel-side intermediate wall.

Clause 20. The iron-type golf club head of clause 14, wherein the membrane further comprises: a heel-side membrane, disposed in the heel-side region, defining a heel-side intermediate wall and at least partially enclosing a heel-side chamber, a toe-side membrane, disposed in the toe-side region, defining a toe-side intermediate wall and at least partially enclosing a toe-side chamber, a connecting wall disposed in the flexure region and extending between the heel-side membrane and the toe-side membrane.

Clause 21. The iron-type golf club head of clause 19, wherein the connecting wall comprises a thin, solid section of the membrane that is independent of the heel-side chamber or the toe-side chamber.

Clause 22. The iron-type golf club head of clause 14, wherein the flexure region comprises a structural discontinuity of the pneumatic insert.

Clause 23. The iron-type golf club head of clause 14, wherein the pneumatic insert is secured within the cavity without any adhesives or separate coupling members.

Clause 24. The iron-type golf club head of clause 14, wherein the pneumatic insert is inflated to an insert pressure of between 0 and 5 psi.

Clause 25. The iron-type golf club head of clause 14, wherein the pneumatic insert is inflated to an insert pressure of between 0.5 and 1.5 psi.

Clause 26. The iron-type golf club head of clause 14, wherein the membrane is formed by a process selected from the group consisting of thermoforming, vacuum forming, pressure forming, mechanical forming, drape forming, matched mold forming, twin sheet forming, and billow forming.

Clause 27. The iron-type golf club head of clause 14, wherein the membrane comprises a membrane thickness less than 0.050 inch.

Clause 28. An iron-type golf club head, comprising: a body comprising: a front end defining a strike face, a top rail, a sole opposite the top rail, a heel, and a toe opposite the heel; a rear end opposite the front end, the rear end defining a rear wall; a cavity at least partially bounded by the strike face, the top rail, the sole, the heel, the toe, and the rear wall, wherein the rear wall extends partially between the sole and the top rail; a pneumatic insert disposed in the cavity and comprising: a membrane enclosing a hollow chamber filled with a pressurized gas, an insert forward surface, an insert rear surface, a central aperture defining a pinched column connecting the insert forward surface and insert rear surface; wherein: the pinched column defines a web connected to and positioned between the insert forward surface and the insert rear surface.

Clause 29. The iron-type golf club head of clause 28, wherein the pinched column is formed using a thermal bonding process.

Clause 30. The iron-type golf club head of clause 28, wherein the pneumatic insert further comprises: a height measured between the insert forward surface and the insert rear surface, an intended pressure level between 0.1 psi and 30 psi; wherein: the height increase by less than 5% for each additional 0.1 psi that the pneumatic insert is inflated beyond the intended pressure level.