FORGED MULTI-COMPONENT PUTTER

Abstract

Multi-component putters have forged, low-density crown components and more dense sole components. The two components comprise complementary geometries that allow for adhering the two components to create a putter head. The crown component and sole component are created to have a split plane and split plane angle, which allows for the sole component to be mostly or entirely hidden by the crown component when viewed at address.

Claims

1. A putter-type golf club head, comprising: a sole component formed of a sole component material having a sole component material density, the sole component including: a sole bottom surface defining at least a portion of a sole of the putter-type golf club head; a sole top surface; a sole projection from a top plan view, the sole projection having a sole projection border that defined a sole projection area; and a crown component formed of a crown component material different from the sole component material and having a crown component material density less than the sole component material density, the crown component including: a crown bottom surface coupled to the sole top surface; a crown top surface defining at least a portion of a crown of the putter-type golf club head; a crown projection from the top plan view, the crown projection having a crown projection border that defines a crown projection area; wherein: the crown projection area encompasses at least 95% of the sole projection area, such that no more than 5% of the sole component is visible from the top plan view; the crown component material comprises a crown component forged material including at least 98% aluminum; and the sole component comprises at least 70% of a total weight of the putter-type golf club head.

2. The putter-type golf club head of claim 1, wherein the crown component further comprises an anodized layer forming the crown top surface.

3. The putter-type golf club head of claim 2, wherein the anodized layer comprises a first color.

4. The putter-type golf club head of claim 3, wherein the anodized layer further comprises a second color different than the first color.

5. The putter-type golf club head of claim 4, wherein the second color forms a second color pattern arranged as an alignment feature.

6. The putter-type golf club head of claim 1, wherein the crown component forged material has a porosity of less than 2.9%.

7. The putter-type golf club head of claim 1, further comprising: a putter head height extending from a ground plane to a top point of a top rail in a direction perpendicular to the ground plane; a putter head maximum perimeter associated with a maximum projected perimeter area from the top plan view; and a split plane parallel to the ground plane and coincident with the putter head maximum perimeter, wherein the split plane is at least 60% of the putter head height above the ground plane.

8. The putter-type golf club head of claim 7, wherein the sole component and the crown component define an overall putter side surface that includes: a side surface lower region below the split plane and extending inwardly from the putter head maximum perimeter at a lower region draft angle; and a side surface upper region above the split plane and extending inwardly from the putter head maximum perimeter at an upper region draft angle.

9. The putter-type golf club head of claim 8, wherein each of the lower region draft angle and the upper region draft angle is 7 degrees.

10. The putter-type golf club head of claim 1, wherein the crown component and the sole component comprise at least one aperture.

11. A putter-type golf club head comprising: a body comprising; a strike face; a sole component made of a first material contributing at least 85% of a total body weight; the sole component further comprising: a sole extending rearward from a bottom of the strike face and having a sole lower surface and a sole top surface; a top rail extending rearward from a top of the strike face and including a lip projecting over the sole top surface; a rear wall joining the sole top surface to the lip of the top rail and defining a rear wall cavity open to a rear of the club; and a crown component made of a second material, coupled to the sole component, the crown component comprising; a crown component front wall disposed in the rear wall cavity of the body; a crown component rear extension overlaying the sole top surface of the body; wherein the lip of the top rail extends over an entirety of the crown component front wall; wherein the first material is denser than the second material; and wherein the second material is at least 98% pure aluminum.

12. The putter-type golf club head of claim 11, wherein the lip defines a lip rear edge located rearward of the crown component front wall and extends from a top end of the body to a heel end of the body.

13. The putter-type golf club head of claim 12, wherein the lip rear edge is linear.

14. The putter-type golf club head of claim 11, wherein the sole comprises a sole recess.

15. The putter-type golf club head of claim 14, wherein the sole recess is configured to receive a sole badge.

16. The putter-type golf club head of claim 11, wherein the crown component further comprises an anodized layer forming a crown top surface.

17. The putter-type golf club head of claim 16, wherein the anodized layer comprises a first color.

18. The putter-type golf club head of claim 17, wherein the anodized layer further comprises a second color different than the first color.

19. The putter-type golf club head of claim 11, wherein the second material forming the crown has a porosity of less than 2.9%.

20. The putter-type golf club head of claim 11, wherein the strike face comprises a strike face insert.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] To facilitate further description of the embodiments, the following drawings are provided in which:

[0007] FIG. 1 illustrates a top perspective view of a multi-component putter.

[0008] FIG. 2A illustrates an exploded perspective view of the multi-component putter of FIG. 1.

[0009] FIG. 2B illustrates a top perspective view of the multi-component putter of FIG. 1 including a reference projection plane.

[0010] FIG. 3 illustrates a bottom perspective view of the multi-component putter of FIG. 1.

[0011] FIG. 4 illustrates a top plan view of the multi-component putter of FIG. 1.

[0012] FIG. 5 illustrates a side elevation view, in cross-section, of the multi-component putter of FIG. 1.

[0013] FIG. 6 illustrates a toe-side, rear, perspective view of the multi-component putter of FIG. 1.

[0014] FIG. 7 illustrates a top, rear perspective view of another embodiment for a multi-component putter.

[0015] FIG. 8 illustrates a front elevation view of the multi-component putter of FIG. 7.

[0016] FIG. 9 illustrates a top plan view of the multi-component putter of FIG. 7.

[0017] FIG. 10 illustrates a side elevation view, in cross-section, for the multi-component putter of FIG. 7.

[0018] FIG. 11 illustrates a heel-side, rear, perspective view for the multi-component putter of FIG. 7.

[0019] FIG. 12 illustrates a bottom perspective view of the multi-component putter of FIG. 7.

[0020] FIG. 13 illustrates a front perspective view of the crown component for the multi-component putter of FIG. 7.

[0021] FIG. 14 illustrates an exploded view of the multi-component putter of FIG. 7.

[0022] FIG. 15 illustrates a top perspective view of another embodiment for a multi-component putter.

[0023] FIG. 16 illustrates a front elevation view of the multi-component putter of FIG. 15.

[0024] FIG. 17 illustrates an exploded perspective view of the multi-component putter of FIG. 15.

[0025] FIG. 18 illustrates a top plan view of the multi-component putter of FIG. 15.

[0026] FIG. 19 illustrates a side elevation view, in cross-section, of the multi-component putter of FIG. 15.

[0027] FIG. 20 illustrates an additional side elevation view, in cross-section, of the multi-component putter of FIG. 15.

[0028] FIG. 21 illustrates a micrograph of a microstructure of ATS #1 in a longitudinal direction.

[0029] FIG. 22 illustrates a micrograph of a microstructure of ATS #1 in a transverse direction.

[0030] FIG. 23 illustrates a micrograph of a microstructure of ATS #2 in a longitudinal direction.

[0031] FIG. 24 illustrates a micrograph of a microstructure of ATS #2 in a transverse direction.

[0032] FIG. 25 illustrates a micrograph of a microstructure of ATS #3 in a longitudinal direction.

[0033] FIG. 26 illustrates a micrograph of a microstructure of ATS #3 in a transverse direction.

DEFINITIONS

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] The term strike face, as used herein, refers to a club head front surface that is configured to strike a golf ball. The term strike face can be used interchangeably with the term face.

[0039] 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 a bulge and/or roll of the strike face.

[0040] The term geometric centerpoint, or geometric center of the strike face, as used herein, can refer to a geometric centerpoint of the strike face perimeter, and at a midpoint of the face height of the strike face. In the same or other examples, the geometric centerpoint also can be centered with respect to an engineered impact zone, which can be defined by a region of grooves on the strike face. As another approach, the geometric centerpoint 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).

[0041] The term ground plane, as used herein, can refer to a reference plane associated with the surface on which a golf ball is placed. The ground plane can be a horizontal plane tangent to the sole at an address position.

[0042] The term loft plane, as used herein, can refer to a reference plane that is tangent to the geometric centerpoint of the strike face.

[0043] The term loft angle, as used herein, can refer to an angle measured between the loft plane and the XY plane (defined below).

[0044] The term face height, as used herein, can refer to a distance measured parallel to loft plane between a top end of the strike face perimeter and a bottom end of the strike face perimeter.

[0045] The term lie angle, as used herein, can refer to an angle between a hosel axis, extending through the hosel, and the ground plane. The lie angle is measured from a front view.

[0046] The depth of the putter-type golf club head, as described herein, can be defined as a front-to-rear dimension of the putter-type golf club head.

[0047] The height of the putter-type golf club head, as described herein, can be defined as a crown-to-sole dimension of the putter-type golf club head. In many embodiments, the height of the putter-type club head can be measured according to a golf governing body such as the United States Golf Association (USGA).

[0048] The length of the putter-type golf club head, as described herein, can be defined as a heel-to-toe dimension of the putter-type golf club head. In many embodiments, the length of the putter-type club head can be measured according to a golf governing body such as the United States Golf Association (USGA).

[0049] The face height of the putter-type golf club head, as described herein, can be defined as a height measured parallel to loft plane between a top end of the strike face perimeter near the top rail and a bottom end of the strike face perimeter near the sole.

[0050] The leading edge of the putter-type club head, as described herein, can be identified as the most sole-ward portion of the strike face perimeter.

[0051] A thickness, as described herein is the length of a line segment connecting two points on opposing surfaces oriented perpendicular to one of the points.

[0052] An XYZ coordinate system of the putter-type golf club head, as described herein, is based upon the geometric center of the strike face. The golf club head dimensions as described herein can be measured based on a coordinate system as defined below. The geometric center of the strike face defines a coordinate system having an origin located at the geometric center of the strike face. The coordinate system defines an X axis, a Y axis, and a Z axis. The X axis extends through the geometric center of the strike face in a direction from the heel to the toe of the fairway-type club head. The Y axis extends through the geometric center of the strike face in a direction from the top rail to the sole of golf club head. The Y axis is perpendicular to the X axis. The Z axis extends through the geometric center of the strike face in a direction from the front end to the rear end of the putter-type golf club head. The Z axis is perpendicular to both the X axis and the Y axis.

[0053] The term or phrase center of gravity position or CG location can refer to the location of the putter-type 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, the Y-axis, and the Z-axis. The term CGx can refer to the CG location along the X-axis, measured from the origin point. The term CG height can refer to the CG location along the Y-axis, measured from the origin point. The term CGy can be synonymous with the CG height. The term CG depth can refer to the CG location along the Z-axis, measured from the origin point. The term CGz can be synonymous with the CG depth.

[0054] The term or phrase CG projection or CG projection point can refer to the location where the CG is projected on the strike face, wherein the projection is taken normal to the loft plane.

[0055] The XYZ coordinate system of the golf club head, as described herein defines an XY plane extending through the X axis and the Y axis. The coordinate system defines XZ plane extending through the X axis and the Z axis. The coordinate system further defines a YZ plane extending through the Y axis and the Z axis. 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 geometric center of the strike face. In these or other embodiments, the putter-type golf club head can be viewed from a front view when the strike face 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 is viewed from a direction perpendicular to the YZ plane.

[0056] The term or phrase moment of inertia (hereafter MOI) can refer to a value derived using the center of gravity (CG) location. The MOI can be calculated assuming the club head includes the body and the hosel structure. The term MOI.sub.xx or I.sub.xx can refer to the MOI measured about the X-axis. The term MOIyy or I.sub.yy can refer to the MOI measured about the Y-axis. The term MOIzz or I.sub.zz can refer to the MOI measured about the Z-axis. The MOI values MOIxx, MOIyy, and MOIzz determine how forgiving the club head is for off-center impacts with a golf ball.

[0057] The term putter, can, in some embodiments, refer to a putter-type club head having a loft angle less than 10 degrees. In many embodiments, the loft angle of the putter can be between 0 and 5 degrees, between 0 and 6 degrees, between 0 and 7 degrees, or between 0 and 8 degrees. For example, the loft angle of the club head can be less than 10 degrees, less than 9 degrees, less than 8 degrees, less than 7 degrees, less than 6 degrees, or less than 5 degrees. For further example, the loft angle of the club head can be 0 degrees, 1 degree, 2 degrees, 3 degrees, 4 degrees, 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees, or 10 degrees. The putter-type golf club head can be a blade type putter, a mid-mallet type putter, a mallet type putter.

[0058] The term split plane can refer to a plane parallel to the ground plane that follows the general contour of the putter exterior surface, along the toe, heel and rear portions and intersects each point on the point at which the draft angle of the toe side and heel side is zero.

Description

I. Multi-Component Putter

[0059] Multi-component putter heads disclosed herein have crown components with improved aesthetics. In some embodiments, the crown components obscure a great majority of a sole or other components when viewed from above, thereby giving the putter a clean, non-distracting appearance that improves a user's focus. Additionally, in some embodiments, the crown component is formed of nearly pure, forged aluminum that has a premium appearance and permits surface features similar to those provide on milled putters, but at a fraction of a milled putter cost.

[0060] The crown component can be formed by forging a low density metal, such as aluminum. Other lightweight materials that may be used include, but are not limited to, titanium, titanium alloys, magnesium, magnesium alloys, beryllium, beryllium alloys, copper, or copper alloys. Forging the crown component, as opposed to the more traditional method of casting, yields a net or near-net shape with reduced porosity relative to that present in casted putter heads. With reduced porosity, the putter heads disclosed herein have improved structural integrity, and can be color treated for a higher quality appearance.

[0061] The improved aesthetics and surface features of the putter heads disclosed herein mimic those of a milled putter head at a fraction of the cost associated with milling. Machining pure aluminum is excessively costly and time consuming. Furthermore, machining parts can result in excess scrap material, which is both expensive and wasteful. Forging putter heads, as disclosed herein, obtains the desired shape with minimal machining. Further, the use of pure aluminum increases the final product quality by eliminating the large amount of impurities needed and resulting from die-casting. Additionally, pure aluminum allows for an anodized finish. Anodizing produces an oxide layer over the aluminum, which is easier to color treat, resists corrosion and does not chip, peel, or crack over time. Color is added by introducing a dye to the porous oxide layer that anodization process produces, which is then absorbed and results in a high-quality finish. Anodizing cannot be done on impure aluminum, such as die-cast aluminum, because the impurities hinder the process by reducing the electrical conductivity of the aluminum. Since die-cast aluminum cannot be anodized, paint is generally used, which easily chips, peels, and cracks. For this reason, using a pure aluminum to form the crown component provides the premium and durable finish of a fully forged club head at a fraction of the cost.

[0062] The forged crown component can be coupled to a sole component formed from a high-density material. A seam is created along the edge where the crown component and sole component join. Forged aluminum (or other low-density metals) crown components, according to the present disclosure, obscure most or all of the seam when viewed at address. This is attributed to the draft angle formed through the forging process. Specifically, the perimeter of the crown component comprises a draft angle that extends over the sole component, wherein the sole component is tapered inwards, towards the sole, and thereby hidden by the higher quality crown component. As described in more detail below, the sole component provides increased perimeter weighting, improving MOI and therefore forgiveness, to impart consistent ball speed and travel distance for repeated putts. The combination of the forged pure aluminum crown component with a hidden seam yields a high MOI putter head with improved aesthetics that can be produced without excessive cost or waste.

[0063] The putter components described herein require minimal machining, thereby reducing the cost. Due to the near-net shape nature of forming the crown and sole component, the two pieces may easily assembled using an adhesive or other coupling method. Additionally, a wide variety of putter head designs can be formed, such as spade shaped, blade shaped, crescent shaped, semi-circular shaped, circular shaped, T-shaped, dual-rail shaped, or winged shaped putters.

II. Crown Component

[0064] In some embodiments, the crown component is forged from aluminum to have a finer, more uniform finish. Forged aluminum also expands the available colors the crown component may have, thereby improving the aesthetics of the putter, and the reduced porosity of the forged aluminum allows finer surface features to be formed. The crown component can be formed separately using methods that produce net or near-net shapes, as well as finish patterns, alignment aids, and aesthetic effects. For instance, the crown component may be forged from a solid billet of pure aluminum, allowing for complex geometries to be created with minimal machining. The complex geometries can include standard putter features such as sightlines, recesses, rails, toplines, etc. In addition, the forging process can imprint a textured design, thereby providing a more finished appearance that would conventionally be achieved by additional and expensive machining. Texturing is adding any type of roughness, or deviation from a flat/smooth surface. The texturing, via the forging process, provides a finished, premium look in a more cost-effective manner.

[0065] A low density metal can be used to form the crown component. In some embodiments, the crown component can be forged from pure aluminum. Pure aluminum can refer to an aluminum material with less than 2% inclusions. In some embodiments, the pure aluminum can comprise less than 2%, less than 1.8%, less than 1.6%, less than 1.4%, less than 1.2%, less than 1.0%, less than 0.8%, less than 0.6%, less than 0.4%, less than 0.2%, or trace amounts of inclusions. The lack of inclusions allows the crown component to be anodized. Anodizing produces an oxide layer over the aluminum, which resists corrosion and does not chip, peel, or crack over time.

[0066] The formation of the oxide layer as well as the lack of inclusions provides a crown component with little to no porosity. Porosity within the crown component can create gaps that allow micro-cracks formed at the surface to extend deeper into the material, which can compromise the structural integrity of the crown component. Further, porosity limits the finishing processes that can be applied. Using aluminum, beryllium, magnesium, or titanium forged crown pieces reduces the level of porosity. Normal levels of porosity in casted aluminum can be higher than 5%. The forged method described herein reduces the percentage of porosity in the crown component to less than 2.9%. In some embodiments the porosity is between 0% and 1%. The percentage of porosity in the crown component can be between 0% and 0.2%, 0.2% and 0.4%, 0.4% and 0.6%, 0.6% and 0.8%, or 0.8% and 1.0%. The percentage of porosity in the crown component can be less than 1%, less than 0.8%, less than 0.6%, less than 0.4%, or less than 0.2%.

[0067] In some embodiments, as shown in FIGS. 4, 9, and 18 the crown component provides a crown faade, when viewed at address, that is coupled to a denser sole component, to provide an aesthetically pleasing view to the user at address. Since the crown component is the main visible component when executing a putting stroke, an aesthetically pleasing top view can be advantageous. Forging the crown component out of a pure aluminum billet has numerous benefits to the overall aesthetic compared to traditional casting. For example, forged aluminum maintains a tight, aligned grain structure, thereby increasing the strength of the crown component and providing a more premium look. Additionally, the single pure billet of aluminum can be anodized to form an oxide layer having a desired color. The use of complementary or contrasting colors can improve aesthetics, increase visibility of features such as sightlines, and otherwise provide a finished, aesthetically pleasing look to the user. The colors are the result of dying the porous oxide layer from the anodization process. Anodized aluminum is more resilient to chipping than traditional painted surfaces. Anodizing further improves durability of the putter as it increases corrosion and wear resistance of the crown component as well as resists denting from impacts of other golf clubs in a golf bag. Forging the crown component into a final or near-net shape with finish patterns, alignment aids, and aesthetic effects removes the need for additional machining.

[0068] In some embodiments, the crown component makes up a significant portion if not the entirety of the putter head body when viewed at address. The crown component can define the visible shape of the putter head. This includes a striking face portion, a top rail, a crown component sole portion, and the top of a rear body segment. In other embodiments, the crown component may not form the striking face and top rail, and instead forms the top of the rear body. The crown component further comprises a geometry that is complementary with the sole component, which allows for simple assembly of the two components. More specifically, the crown component can comprise a crown top surface and crown bottom surface, wherein the crown bottom surface receives a sole top surface, as discussed in depth below.

[0069] The crown component can comprise a crown component mass. The crown component mass can be between 25 g and 165 g. The crown component mass can be between 30 g and 35 g, 35 g and 40 g, 40 g and 45 g, 45 g and 50 g, 50 g and 65 g, 65 g and 70 g, 70 g and 75 g, 75 g and 80 g, 80 g and 85 g, 85 g and 90 g, 90 g and 95 g, 95 g and 100 g, 100 g and 105 g, 105 g and 110 g, 110 g and 115 g, 115 g and 120 g, 120 g and 125 g, 125 g and 130 g, 130 g and 135 g, 135 g and 140 g, 145 g and 150 g, 150 g and 155 g, 155 g and 160 g, or 160 g and 160 g. The crown component mass can make up between 5% and 45% of the putter head total mass. The crown component mass can make up between 5% and 10%, 10% and 15%, 15% and 20%, 20% and 25%, 25% and 30%, 30% and 35%, 35% and 40%, or 40% and 45% of the putter head total mass.

[0070] The size and shape of the crown component further can be described with reference to a crown projection extending from the crown component in a direction perpendicular to the ground plane. As shown in FIG. 2B, the crown projection can be constrained by a crown projection border defined as a perimeter of the crown component from a top plane view. The crown projection border defines a crown projection area. In some embodiments, the crown projection border coincides with the split plane. The split plane is a plane that defines the outermost perimeter of the putter head. Specifically, the split plane defines an inflection point where the draft angle changes from angling toward the crown to angling towards the sole. The seam between the crown component and the sole component may generally be below the split plane, but in some components, the seam may be even with or above the split plane. The crown projection is mostly made up of the crown component, such that the crown component is predominantly visible at address. In some cases the crown component makes up over 99% of the crown projection. This can be attributed to the wrapping of the crown component around the split plane and the draft angles associated with perimeter of the putter head.

III. Sole Component

[0071] The multi-component putter further comprises a sole component located below the crown component that generally forms a bottom of the putter head. In some embodiments, the sole component may form the striking face and/or the top rail. In other embodiments, the striking face and/or the top rail may be formed by the crown component.

[0072] The sole component can contribute most of the putter head weight, as it is formed from a denser material than the crown component. For example, the sole component may be formed of a stainless steel or other dense material, having a greater density than the material used to form the crown component. The sole component may comprise thicker regions in the heel, toe, and/or rear side of the putter head to create more perimeter weighting and increase the MOI. A higher MOI results in a more forgiving putter that twists less and more evenly transfers energy to the ball on off-center strikes. The sole component may be formed using techniques such as coining, casting, or metal injection molding (MIM). Generally, the sole component is formed using a cheaper method, which helps reduce the cost of the overall putter, and is satisfactory since the sole component is not largely visible at address.

[0073] The sole component comprises a sole component top surface and a sole component lower surface. The sole component lower surface generally creates a majority of the sole, which is substantially flat. In certain embodiments the sole may comprise a heel-to-toe and/or front-to-rear camber that allows the putter to glide on top of the ground, rather than snag on the ground. The sole component top surface has a geometry that matches the crown lower surface, such that the two components are complementary.

[0074] As seen in FIGS. 2A, 14, and 17 the sole component can further comprise a toe mass and a heel mass. The weights of the heel mass and toe mass can be selected to achieve a desired swing weight or overall putter head mass. The toe mass and heel mass are located proximate the toe end and the heel end, respectively, and may be integral with/formed from the same material as the sole component. In other embodiments, the toe mass and the heel mass can be formed of a different material than the sole component with a density greater than the density of the sole component material. The toe mass and heel mass extend vertically from the sole component in a direction away from the ground plane. The toe mass and heel mass provide a means to position and align the crown component with the sole component to form the putter head body.

[0075] Furthermore, the toe mass and heel mass add to the perimeter for increasing the MOI. The toe mass and heel mass can have masses that range from 10-40 grams. In some embodiments, the toe mass and heel mass can comprise a mass of approximately 25 grams each. In some embodiments, the toe mass and heel mass can have masses that range from 10-25 grams, 15-30 grams, 20-35 grams, or 25-40 grams. In some embodiments, the toe mass 1741 and heel mass 1743 can have masses that range from 10-20 grams, from 15-25 grams, from 20-30 grams, from 25-35 grams, or from 30-40 grams. In some embodiments the toe mass 1741 and heel mass 1743 can comprise a mass of approximately 15 grams, 16 grams, 17 grams, 18 grams, 19 grams, 20 grams, 21 grams, 22 grams, 23 grams, 24 grams, 25 grams, 26 grams, 27 grams, 28 grams, 29 grams, 30 grams, 31 grams, 32 grams, 33 grams, 34 grams, or 35 grams.

[0076] The toe mass and heel mass can each have the same mass or can comprise different masses within the ranges provided above. The toe mass and heel mass, respectively, can be any one or a combination of the following shapes: rectangular, triangular, pyramidal, spherical, crescent-shaped, square, cylindrical, ovular, elliptical, trapezoidal, pentagonal, hexagonal, octagonal, or any other desired geometric or non-geometric shape.

[0077] The toe mass and heel mass provide areas of concentrated mass, such that the toe mass and heel mass increase the moment of inertia of the putter head. The placement of the toe mass and the heel mass on or near the toe end and the heel end, respectively, increases the MOI by shifting mass away from a center of gravity of the putter head.

[0078] The sole component can comprise a sole component mass. The sole component mass can be between 175 g and 375 g. The sole component mass can be between 175 g and 185 g, 185 g and 195 g, 195 g and 205 g, 205 g and 215 g, 215 g and 225 g, 225 g and 235 g, 235 g and 245 g, 245 g and 255 g, 255 g and 265 g, 265 g and 275 g, 275 g and 285 g, 285 g and 295 g, 295 g and 305 g, 305 g and 315 g, 315 g and 325 g, 325 g and 335 g, 335 g and 345 g, 345 g and 355 g, 355 g and 365 g, or 365 g and 375 g. The sole component mass can make up between 50% and 95% of the putter head total mass. The sole component mass can make up between 50% and 55%, 55% and 60%, 60% and 65%, 65% and 70%, 70% and 75%, 75% and 80%, 80% and 85%, 85% and 90%, or 90% and 95% of the putter head total mass.

[0079] The sole component comprises a sole component top surface and a sole component lower surface. The sole component lower surface generally creates a majority of the sole, which is substantially flat. In certain embodiments the sole may comprise a heel-to-toe and/or front-to-rear camber that allows the putter to glide on top of the ground, rather than snag on the ground. The sole component top surface has a geometry that matches the crown lower surface, such that the two components are complementary.

[0080] As described above with the crown component and as shown in FIG. 2B, the size and shape of the sole component can further be described with reference to a sole projection extending from the sole component in a direction perpendicular to the ground plane. The sole projection can be constrained by a sole projection border defined as a perimeter of the sole component from a top plane view. The sole projection border defines a sole projection area. The sole projection border can coincide with the split plane. In other casted multi-component putters, this split line does not always hide the sole component. For instance, it is common to see the sole component over a portion of the crown component at address, which can be distracting to the user.

[0081] In some embodiments, the sole component can comprise a sole component recess designed to receive a sole badge, shown in FIG. 3. The sole badge can provide aesthetic features to the bottom of the putter head. Applying designs and other aesthetics directly on the sole of a putter head can increase cost as milling and machining is slower and less cost efficient. The sole badge allows for a separate, thin piece to be manufactured by stamping, such that the sole badge has the desired aesthetic design imprinted. Following stamping, the sole badge may be paint filled and finished to yield a final design. The sole badge can then adhere within the sole component recess. The sole badge may be constructed from a metallic, composite, or multi-material (such as plated acrylonitrile butadiene styrene (ABS)).

[0082] The sole component recess can comprise a recess depth measured from an exterior surface of the bottom surface of the sole component to an interior surface of the sole component, in a direction perpendicular to the ground plane. In some embodiments, the recess depth can be between 0.020 inches and 0.050 inches. In other embodiments, the recess depth can be between 0.020 inches and 0.055 inches, between 0.025 inches and 0.030 inches, between 0.030 inches and 0.035 inches, between 0.035 inches and 0.040 inches, between 0.040 inches and 0.045 inches, or between 0.045 inches and 0.050 inches.

[0083] The sole badge can comprise a sole badge thickness. The thickness can ensure the sole badge fits within the sole component recess and the curvature of the sole remains uninterrupted. In some embodiments, the sole badge will be between 0.020 inches and 0.050 inches. In other embodiments, the sole badge thickness can be between 0.025 inches and 0.030 inches, between 0.030 inches and 0.035 inches, between 0.035 inches and 0.040 inches, between 0.040 inches and 0.045 inches, or between 0.045 inches and 0.050 inches.

[0084] The sole badge can further comprise a sole badge mass. In some embodiments, the sole badge mass can be between 3.0 grams and 31.0 grams. In some embodiments, the sole badge mass can be between 3.0 grams and 5.0 grams, 5.0 grams and 7.0 grams, 7.0 grams and 9.0 grams, 9.0 grams and 11.0 grams, 11.0 grams and 13.0 grams, 13.0 grams and 15.0 grams, 15.0 grams and 17.0 grams, 17.0 grams and 19.0 grams, 19.0 grams and 21.0 grams, 21.0 grams and 23.0 grams, 23.0 grams and 25.0 grams, 25.0 grams and 27.0 grams, 27.0 grams and 29.0 grams, or 29.0 grams and 31.0 grams. In some embodiments, the sole badge mass can be between 20.0-23.0 grams, 23.0-26.0 grams, 26.0-29.0 grams, or 29.0-31.0 grams. The sole badge mass can make up between 1% and 15% of the sole component mass. The sole badge mass can make up between 1% and 2%, 2% and 3%, 3% and 4%, 4% and 5%, 5% and 6%, 6% and 7%, 7% and 8%, 8% and 9%, 9% and 10%, 10% and 11%, 11% and 12%, 12% and 13%, 13% and 14%, or 14% and 15% of the club head total mass.

IV. Strike Face

[0085] The multi-component putter head may further comprise a strike face. In some embodiments, the strike face can be formed integrally with the crown component, integrally with the sole component, as seen in FIG. 10, or as a separate component such as a strike face insert, as seen in FIGS. 3 and 16. In some embodiments, the strike face can form a single material and in other embodiments, the strike face can be formed from multiple materials creating a multi-material strike face.

[0086] The strike face can comprise a milling pattern. The milling pattern can comprise a plurality of milling lines that extend in a vertical, horizontal, curvilinear, arcuate, or circular direction across the strike face. The milling pattern can extend in a crown to sole direction, and/or in a heel to toe direction across the strike face. The milling pattern enhances the surface finish of the putter head or strike face to improve the appearance of the putter head.

[0087] In some embodiments, the strike face comprises a strike face insert that is independently formed prior to being coupled to the club head. In some embodiments, the strike face insert can make up the entire strike face. In other embodiments, the strike face insert can make up a central portion of the strike face. In some embodiments, a strike face toe side and a strike face heel side can be formed integrally with the crown component or with the sole component. In some embodiments, the strike face can form a portion of the sole.

[0088] The strike face insert may comprise a complementary geometry to a strike face recess. This provides a surface to couple the insert to the strike face. The strike face insert can comprise a single component system formed of a single material, or a two-component system formed from one or more materials. In some embodiments, the strike face insert can comprise the same material as the crown component. In some embodiments, the strike face insert can comprise the same material as the sole component. In some embodiments, the strike face insert can comprise the same material as the sole badge.

[0089] The strike face insert can be secured to the club head by a fastening means. In some embodiments, the strike face insert can be secured to the crown component. In these embodiments, the crown component defines an insert cavity in a forward portion of the crown component. The crown component insert cavity is configured to receive the strike face insert. Further, in these embodiments, when the strike face insert is affixed to the crown component, the crown component encompasses the strike face insert on at least two sides of the strike face insert. The strike face insert is configured to mate with the crown component insert cavity. In other embodiments, the strike face can be secured to the sole component. In these embodiments, the sole component can comprise an insert cavity. The sole component insert cavity functions to receive the strike face insert. Further, in these embodiments, when the strike face insert is affixed to the sole component, the sole component encompasses the strike face insert on at least two sides. The strike face insert is configured to mate with the sole component insert cavity. The strike face can be secured by an adhesive such as glue, very high bond (VHB) tape, epoxy or another adhesive. Alternately or additionally, the strike face can be secured by welding, soldering, screws, rivets, pins, mechanical interlock structure, or another fastening method.

[0090] The strike face can be made of various materials depending upon the customization of the putter head. The strike face insert can comprise any one or a layered combination of the following: aluminum, stainless steel, copper, thermoplastic co-polyester elastomer (TPC), thermoplastic elastomer (TPE), thermoplastic urethane (TPU), steel, nickel, TPU/aluminum, TPE/aluminum, plastic/metal screen insert, polyethylene, polypropylene, polytetrafluoroethylene, polyisobutylene, polyvinyl chloride, PEBAX, or any other desired material. PEBAX is a polyether block amide that is a thermoplastic elastomer made of a flexible polyether and rigid polyamide. The rigid polyamide can comprise Nylon. The PEBAX can comprise different compounds that correspond to different Shore D hardness values, polyether percentages, and/or polyamide percentages. In many embodiments, the PEBAX can comprise a PEBAX 4033 (Arkema, Paris France) or a PEBAX 6333 (Arkema, Paris France). The PEBAX 4033 (Arkema, Paris France) comprises a tetramethylene oxide (53% wt) and a Nylon 12. The PEBAX 6333 (Arkema, Paris France) comprises a Nylon 11. In some embodiments, the face insert can comprise a material such as steel, steel alloys, tungsten, tungsten alloys, aluminum, aluminum alloys, titanium, titanium alloys, vanadium, vanadium alloys, chromium, chromium alloys, cobalt, cobalt alloys, nickel, nickel alloys, other metals, other metal alloys, composite polymer materials or any combination thereof.

[0091] The strike face insert described in this disclosure can be formed by a number of different processes. The strike face material is chosen for durability, reactivity, and its ability to produce a good roll. The different forming processes include the following: injection molding, casting, blow molding, compression molding, co-molding, laser forming, film insert molding, gas assist molding, rotational molding, thermoforming, laser cutting, 3-D printing, forging, stamping, electroforming, machining, molding, or any combination thereof.

V. Assembled Putter

[0092] As shown in FIGS. 5, 10, 19, and 20, the crown component, sole component, sole badge, and strike face cooperate to form a complete putter head comprising improved performance and aesthetics. The crown component and the sole component comprise a complementary geometry. Nesting contours exist for the top surface of the sole component and the bottom surface of the crown component. Therefore, nesting contours provide the means to hide the sole component, by allowing the crown component to easily cover almost the entirety of the sole component (from an address position). The crown component and the sole component of the putter-type golf club head can be joined in any one or combination of the following methods: welding, soldering, brazing, swedging, adhesion, epoxy, or mechanical fastening. In some embodiments, the crown component and the sole component can be joined by adhesion with epoxy, polyurethanes, resins, hot melts, or any other adhesive. Once joined a seam is created at the edges where the crown component joins the sole component. The seam is not visible to the user at address.

[0093] As seen in FIGS. 6, 8, and 16, the split plane is formed with the split plane angle, wherein the edge of the putter head is angled inward from the split plane. The split plane angle and described further below creates a more visually appealing look at address. Specifically, it can be located such that only the crown component is visible at address, thereby obscuring the sole component. Since the crown component and sole component are different materials, with different finishes, seeing the sole component could be distracting to the user. Additionally, only having the crown component visible provides a more premium, aesthetically pleasing look by giving the appearance of a unitary body. Milled putters provide premium aesthetics and are generally milled from a single workpiece, which results in a unitary piece. This, however, comes at a higher cost relative to forging. Forging is desirable to achieve a premium look at a lower cost.

[0094] The split plane may define upper and lower portions of the golf club head, such that, in a top-down direction, the upper portion protrudes outward to a widest point, and the lower portion is angled inward towards the sole. The split plane is located so that, at address, the seam is not visible, and a majority of the sole component is hidden by the crown component. This provides the look of a unitary body, with no additional pieces, that can be distracting to the user. This split plane may extend through both the crown component and sole component, exclusively the crown component, or exclusively the sole component. A split plane angle 152 may be between 4 degrees and 10 degrees, wherein the upper and lower portion of the split plane form half of the total split plane angle. In some embodiments, the split plane angle may be 4 degrees, 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees, or 10 degrees. In a preferred embodiment, the split plane angle is 7 degrees, wherein the upper and lower portions of the split plane angle are each 3.5 degrees. If the split plane angle is too small, the user will be able to see the sole component, which is not desired. If the split plane angle is too large, the split plane will be visible and the putter aesthetics will be undesirable and be less stable when resting on the ground. The split plane is formed in the forging and/or casting/MIM phase of the manufacturing process.

[0095] Once assembled, a percentage of the total club head mass can be located below the split plane (hereafter alternately refer to as the split plane percentage). Again, mass is preferred in the sole component to achieve a lower center of gravity. Once assembled, a percentage of the total club head mass located below the split plane can be between 60% and 90%. The split plane percentage can be between 60% and 62%, 62% and 64%, 64% and 66%, 66% and 68%, 68% and 70%, 70% and 72%, 72% and 74%, 74% and 76%, 76% and 78%, 78% and 80%, 80% and 82%, 82% and 84%, 84% and 86%, 86% and 88%, or 88% and 90%.

[0096] As previously mentioned, the crown component can comprise a crown projection having a crown projection area and the sole component can comprise a sole projection having a sole projection area. Once assembled the crown projection area can cover a percentage of the sole projection area, when overlayed and viewed by a user at address. In some embodiments, once assembled the crown projection area can cover between 60% and 100% of the sole projection area. The crown projection area can cover between 60% and 65%, 65% and 70%, 70% and 75%, 75% and 80%, 80% and 85%, 85% and 90%, 90% and 95%, or 95% and 100% of the sole projection area. In some embodiments, the crown projection area can cover more than 60%, more than 65%, more than 70%, more than 75%, more than 80%, more than 85%, more than 90%, or more than 95% of the sole projection area. When assembled, no more than 25% of the sole projection area is visible at address. In other embodiments, no more than 25%, no more than 20%, no more than 15%, no more than 10%, or no more than 5% of the sole projection area is visible at address. In a preferred embodiment no more than 5% of the sole projection area is visible at address.

[0097] A crown projection that covers a majority of the sole projection creates the faade of a forged unitary body putter head when viewed at an address position, for a fraction of the price. This faade ensures the user's eye is focused on the golf ball and is not drawn to the seam formed by the joining of the crown component and the sole component. This helps utilize the quiet eye phenomenon. The quiet eye phenomenon is defined as the final fixation or tracking gaze at a task-relevant location prior to the initiation of the final phase of movement. The initiation of the final phase of movement for a putting stroke is the backstroke (or pulling the putter head away from the ball) prior to the forward stroke to strike the golf ball. Studies have found high levels of performance (i.e., putting well) occur when a person's focus, or eye, lingers on a the ball before and during the putt and then fixates at the point of contact. In golf, this translates to focusing on the ball at the time of address and throughout the entirety of the putting stroke. A visible seam can distract the user's eyes by drawing the gaze towards the seam and away from the golf ball.

[0098] Additionally, the crown component can be described as a relationship between the crown component mass percentage of the total putter mass to the crown projection area. For instance, in some embodiments, the crown component can make up 15% of the total mass and have a crow projection covering 72% of the sole projection. In this embodiment, the crown mass to crown projection ratio may be 0.21. In other embodiments, the crown mass to crown projection ratio may be between 0.15 and 0.50. In some embodiments, the crown mass to crown projection ratio may be between 0.15 and 0.20, between 0.20 and 0.25, between 0.25 and 0.30, between 0.30 and 0.35, between 0.35 and 0.40, between 0.40 and 0.45, or between 0.45 and 0.50.

VI. Manufacturing

[0099] The crown component 110 and the sole component 120 may be formed in different manners. Specifically, the crown component 110 may be formed through a forging process with a lightweight metal (such as aluminum) and the sole component 120 may be formed through a casting or metal injection molding (MIM) process with a dense metal (such as steel).

[0100] Forging the crown component 110 advantageously provides a more aesthetically pleasing putter top view. Specifically, forging allows for a purer form of metal to be used, compared to die-casting. In the case of aluminum, die-casting lightweight metal crown components 110 require flow agents to be added that help molten aluminum fully occupy the mold. The flow agents, however, introduce impurities that can affect grain structure and finish quality. For instance, casting will have a grain structure that is rougher than that achieved by forging, and impurities will affect finishing via anodizing. Specifically, these impurities inhibit the electrical conductivity required to anodize the aluminum, resulting in a less uniform/weaker oxide layer. Therefore, there is emphasis placed on having a substantially pure crown component 110 material.

[0101] In some embodiments, forging the crown component 110 includes three separate forging steps. In each step, the billet is heated to between 750 C. to 900 C. First, a billet is rough forged into a general shape. Second, an intermediate forging step is used to shape the crown component 110 into a near final shape. Third, a final forging step gives the crown component 110 its final shape. Each forging step aids in changing the material grain structure through dynamic recrystallization. Following a forging step, the crown component 110 may be machined to remove excess flash material and correct for any other potential defects. The forging steps may also be used to include sightlines and textures on the crown or face that traditionally are created through additional machining. Reducing the amount of additional machining serves as a time and monetary cost benefit. Further, the crown component 110 may be anodized (as discussed above) to achieve a desired color, which is aided by the purity of the aluminum.

[0102] Additionally, forging can provide improved surface roughness characteristics relative to milling. For instance, Rz is a measure of tallest peaks to valleys on a surface and Ra is the average surface roughness. Ra is generally lower for precision forged pieces compared to milled components. Specifically, precision forged pieces will have an Ra value between 4 and 8 micrometers. Milled putters will generally have an Ra value between 6.3 and 12.5 micrometers, so on average precision forging produces a smoother surface. With the precision forging steps carried out in manufacturing the crown component, Rz values are generally higher than forging, resulting in a larger discrepancy between the surfaces' highest and lowest points. Typically, the milling will be double the Ra value (e.g. between 12.6 and 25.0 micrometers), while the forged piece will be closer to the Ra value (between 4 and 8 micrometers). This shows that forging produces a generally smoother surface than milling.

[0103] In some embodiments, the sole component 120 is manufactured through casting or a MIM process using a metal that is denser than the crown component 110 to form a heavy sole component 120 that makes up a majority of the overall head mass. The crown component 110 and sole component 120 are formed to have a complementary geometry, such that the crown component 110 and sole component 120 may be easily coupled together. In some embodiments, the sole component 120 may be formed using a MIM or multi-density MIM technique. A multi-density MIM allows for multiple materials within a sole component 120, in a unitary body. For instance, a second material (such as tungsten) may be included in the sole component 120 that is denser than a first sole component material. The denser metal may be located at the perimeter of the putter head to improve MOI and/or increase head weight, while still having a unitary look.

[0104] Forged aluminum putter heads provide significant savings relative to fully machined golf club heads, while fully casted clubs remain the cheapest option, but sacrifice aesthetics and quality to stay at a cheaper price point. Milling allows for a premium, unitary body, but at the sacrifice of long lead times and high costs. The multi-component putter, described herein, can be manufactured with a premium look at a quicker rate and at a cheaper cost, relative to fully machined putters. In some instances, a fully machined putter head may cost approximately $82 per head, while the forged multi-component putter can be produced at approximately $57 per head. From a top plan view, which is how a user views the putter when in use, both putter heads may appear identical. An identical look at address for approximately 30% financial savings is desirable to control overall cost. Additionally, less waste material is produced compared to milling as machining is a subtractive manufacturing process and forging requires minimal material removal. In some instances, forging a multi-component putter head offer savings over 30%, compared to fully machined putter heads.

VII. Embodiments

A. Spade Shaped Mallet

[0105] FIGS. 1-6 illustrate a spade shaped multi-component putter, comprising a body 100 which substantially comprises a crown component 110 and a sole component 120. Additionally, the body 100 comprises a hosel 101, a sole badge 130, and a strike face 107 with a strike face insert 140. The strike face insert 140 may comprise a single material or multiple materials. For instance, a first strike face material 140a may be coupled to a second strike face material 140b to achieve a desirable feel and performance. The first strike face material 140a and second strike face material may comprise different durometers. Additionally, the strike face 107 may comprise grooves 143 or a milling pattern to achieve a desired feel. The body is constructed by coupling the crown component 110 to the sole component 120, with the sole badge 130 coupled to the sole component and the strike face insert 140 coupled to the crown component 110. In other embodiments, the sole badge 130 and/or strike face insert 140 may be omitted. The crown component 110 is formed of a different material (such as aluminum) than the sole component material, having a crown component density that is less than a sole component density.

[0106] The crown component 110 generally forms the upper portion of the body and is made of pure, forged aluminum. The forging process creates a near net shaped crown component 110 comprising a top rail 105, the strike face 107, a crown top surface 111, a crown bottom surface 112, a central region 114, a thickened front region 115, a toe wing 116, a heel wing 117, and a crown perimeter surface 118. The crown component 110 is forged to have a shape that is complementary of the sole component 120, such that the two pieces may be coupled together. Additionally, the forging process may also be used to create an alignment feature 113, such as the line through the central region 114 in FIG. 4.

[0107] The crown component 110 comprises four distinct surfaces, including the strike face 107, the crown top surface 111, the crown bottom surface 112, and the crown perimeter surface 118, wherein three surfaces are fully visible upon assembly. The only partially non-visible surface is the crown bottom surface 112, which serves as a mating surface to adhere to the sole component 120, but also creates a visible portion of the sole 123 near the strike face 107. The crown top surface 111 is opposite the crown bottom surface 112 and is the only visible surface at address (illustrated in FIG. 4). This includes the top surface of the top rail 105, the central region 114, the toe wing 116, and the heel wing 117. The top rail 105 comprises the highest surface of the crown top surface 111, while the central region is the lower surface. The toe wing 116 and heel wing 117 may be rounded and raised relative the central region 114 but remain below the top rail 105 height. The top rail extends in a heel 103 to toe 102 direction, while the central region 114, toe wing 116, and heel wing 117 extend toward the rear 104 and perpendicular from the top rail 105. The strike face 107 and crown perimeter surface 118 form the perimeter of the body 100. The strike face 107 is flat and may comprise a recessed region to accept a strike face insert 140, but in some embodiments, the strike face 107 is only made up of the crown component 110 material. The crown perimeter surface 118 serves as a transition between the crown top surface 111 and the crown bottom surface 112 and circumferentially extends around the body 100, excluding the strike face 107. This surface comprises a split plane 150, wherein below the split plane 150 the crown perimeter surface 118 is angled inward, toward the sole 123, while above the split plane 150 it is angled inward toward the crown 109. This split plane 150 passes through both crown component 110 and the sole component 120, with a majority being through the crown component 110. The split plane 150 further comprises a split plane angle 152 (illustrated in FIG. 6) that allows for only the crown component 110 being nearly 100% visible at address. In one embodiment, this split plane angle 152 may be 7 degrees.

[0108] The sole component 120 creates a heavy, rearward, perimeter weighting in the body. It is a separate piece that is coupled to the crown component 110 and contributes the greatest amount of mass to the overall putter head. In this embodiment, the sole component 120 contributes between 55% and 70% of the overall putter head mass. Specifically, the sole component may contribute approximately 60% of the overall putter head mass. The sole component may be cast or MIMd of a higher density material than aluminum to be the main contributor to the overall weight of the golf club head. This low, perimeter weighting provides desirable mass properties, such as a low and rearward center of gravity. This improves MOI and reduces golf ball skidding.

[0109] The sole component 120 comprises a sole top surface 124 and a sole bottom surface 125. Additionally, the sole component comprises a toe mass 121 and a heel mass 122, which are thickened regions near the perimeter, on the toe end 102 and heel end 103, respectively. The sole top surface 124 has a complementary geometry to the crown bottom surface 112, such that the two components are easily coupled via an adhesive. In some embodiments, the sole bottom surface 125 may make up a significant portion of the sole 123, but in other embodiments, the sole bottom surface may comprise a sole recess 126 that allows for a sole badge 130 to be adhered flush within the sole recess 126. The sole 123 may then comprise portions of the crown component 110, sole component 120, and sole badge 130. This is best shown in FIG. 5, which illustrates a cross-sectional through the middle of the body (plane A). In other embodiments, the sole recess 126 and sole badge 130 may be excluded, thus the sole 123 is made of only the crown component 110 and sole component 120.

[0110] The assembled putter creates a crown projection 169 and a sole projection 170, which are the visible portions of the crown component 110 and sole component 120 at address. In some embodiments of the spade shaped mallet putter, the crown projection 169 accounts for 9.79 in.sup.2, while the sole projection accounts for 0.0259 in.sup.2. This equates to approximately 99.7% of the address view being from the crown component 110. The lack of sole projection 170 allows for a premium, unitary body aesthetic that is non-distracting to the user. The split plane 150 and split plane angle 152 act to produce this desirable aesthetic.

B. Mid-Mallet

[0111] FIGS. 7-14 illustrates a multi-component putter that is a mid-mallet style putter that includes a body 200 comprising a toe end 202, a heel end 203, a rear end 204, a crown component 210, a sole component 220, and a sole 223. While this embodiment is discussed separately from the multi-component putter 100 disclosed herein, it should be appreciated that features of the multi-component putters 100 and 300 can be incorporated into any of the embodiments of the multi-component putter 200 to provide a putter that both has adjustable weighting and can adjust a resting face angle.

[0112] A hosel 201 and a strike face 207 can be integrally formed with the sole component 220 such that the aforementioned components are formed from a single material. In some embodiments, the strike face 207 may also comprise a strike face insert 240. The sole component 220 can have a sole bottom surface 225 and a sole top surface 224. A portion of the sole bottom surface 225 can form a portion of a sole 223 that extends rearward from the bottom of the strike face 207. A portion of the sole bottom surface 225 can be configured to receive a sole badge 230. More specifically, the sole bottom surface 225 can comprise a sole recess 226 that is configured to receive a sole badge 230, such that the sole badge 230 forms a portion of the sole 223. A top rail 205 extends rearward from a top of the strike face 207 and forms a lip 206 projecting over the sole top surface 224. The body 200 can further comprise a rear wall 227 that joins the sole top surface 224 to the lip 206 of the top rail 205 and defines a rear wall cavity 228 open to a rear 204 of the putter head.

[0113] The multi-component putter further comprises a crown component 210 (FIG. 13) coupled to the body 200 and harbored within the rear wall cavity 228. The crown component 210 can comprise a crown top surface 211 having an alignment feature 213, and a crown bottom surface 212 configured to overlaying the sole top surface 224. The crown bottom surface can conform the shaping of the sole top surface 224, such that it follows the contour formed by a toe mass 221 and a heel mass 222 of the sole component 220. A portion of the crown component 210 can extend relatively flatly from the rear 204 and a crown component front wall extends upward to meet the lip 206. Such that the crown component 210 covers the rear wall 227. The lip 206 of the top rail 205 extends over an entirety of the crown component front wall 215, thereby concealing the crown component front wall 215 as well as the seam formed by the joining or the crown component 210 and the sole component 220, when viewed by the user at address. The lip 206 can further define a lip rear edge located rearward of the crown component front wall 215 and extending from a top end of the body to a heel end of the body. In some embodiments, the lip rear edge can be linear, while in other embodiments, the lip rear edge can be non-linear.

[0114] The crown component 210 and the sole component 220 comprise complementary geometry. The crown component 210 is coupled to the sole component 220 and conforms to fit within the rear wall cavity 228 defined within the sole component rear wall 227, as shown in FIG. 10. As seen in FIG. 9, the top part of the crown component harbors within the lip of the top rail. When assembled, the lip 206 conceals the seam between the crown component 210 and the sole component 220. This provides the putter head with a more desirable, bifurcated look at address.

[0115] The body 200 of the multi-material head can have a body shape that includes different tier regions which can create an identical cascading structure. When coupled together, the configuration creates a snap fit between the sole component 220 and the crown component 210. The body 200 can comprise a central region 214, an upper tier region, a middle tier region, and a lower tier region. The top rail 205 comprises the highest surface of the crown top surface 211, while the central region 214 is the lower surface. The upper tier region can be located towards the top rail 205 of the club head. The lower tier region can be located towards the rear end 204. The middle tier region can be located between the upper tier region and the lower tier region. The different tier regions can create a cascading structure when observed from a cross-sectional view (FIG. 10) and a back view (FIG. 7). The tiered structure creates a successive thinning from the top rail 205 towards the rear end 204.

[0116] The multi-component putter body 200 may comprise a split plane 350 with a split plane angle 250 that aids in obscuring the sole component 220 from address. The split plane 250 is a plane that intersects the region where the draft angle of the outer surface changes. For instance, below the split plane 250, the body 200 is drafted inward, towards the sole 223 and above the split plane 250, the body is drafted inwards, towards the top. Generally, the split plane is parallel to the ground plane 1010 and the split plane angle 252 is measured from a plane 1035 perpendicular to the ground plane 1010 that abuts the point the draft angle changes. This split plane 250 comprises a split plane angle 252 (illustrated in FIG. 8) that allows for the sole component 220 to be hidden below the crown component 210 at address (excluding the top tail). In some embodiments, the split plane angle is 7 degrees. Hiding the sole component 220 and the seam created by the joining of the crown component 210 and the sole component 220 from the top view is aesthetically desirable as seeing additional parts can be distracting to the user. It also offers a cleaner, more premium look at address.

[0117] The assembled putter creates a crown projection and a sole projection, which are the visible portions of the crown component 210 and sole component 220 at address. In some embodiments of the mid-mallet putter, the crown projection accounts for 5.46 in.sup.2, while the sole projection accounts for 2.11 in.sup.2. This equates to approximately 72% of the address view being from the crown component 210. This value is lower due to the sole component 220 making up the top rail 205. In this embodiment, the top rail differing from the crown projection can aid in alignment and promote a more forward center of gravity. This allows the putter head to have mass properties closer to a blade style putter, which is desirable to some. It is worth noting that rearward of the top rail 205, the crown projection is nearly 100%, which again allows for a premium aesthetic that is non-distracting to the user. The split plane 150 and split plane angle 152 act to produce this desirable aesthetic.

C. Mallet with Apertures

[0118] FIGS. 15-20 illustrates another embodiment of a multi-component putter that is a mallet-style putter having through apertures. The putter includes a body 300 comprising a toe end 302, a heel end 303, a rear end 304, a crown component 310, a sole component 320, and at least one aperture 308. In some embodiments, the body may comprise an alignment feature 313 to aid the user in aiming the putter. While this embodiment is discussed separately from the multi-component putters 100, 200 disclosed herein, it should be appreciated that features of the multi-component putters 100 and 200 can be incorporated into any of the embodiments of the multi-component putter 300 to provide a putter that both has adjustable weighting and can adjust a resting face angle.

[0119] A hosel 301 and a strike face 307 can be formed from the crown component 310 such that the strike face 307 is only made up of the crown component material or includes a strike face insert 340. The crown component 310 further comprises a crown top surface 311 and a crown bottom surface 312. The sole component 320 also comprises a sole bottom surface 325 and a sole top surface 324. The crown component 310 and sole component 320 have complementary geometries that allow the two pieces to easily mate, with the crown bottom surface 312 coupling to the sole top surface 324. To aid in the coupling, locating or locking features 355 may be included to properly orient the two pieces and/or provide a more secure bond. The crown top surface 311 makes up the top of the body 300. The sole 323, which extends rearward from the from the bottom of the strike face 307, however, can be made up from different components. For instance, the sole 323 may strictly be made of only the sole bottom surface 325. In other embodiments, the sole bottom surface 325, the crown bottom surface 312, the strike face insert 340, and/or a sole badge may make up the sole 323. Any combination of these components can create the sole 323. An example of a three-component sole 323 is shown in FIGS. 19 and 20, which are cross-sectional views through plane C (middle of body 300) and plane D (middle of heelside aperture 315a), respectively. Wherein a sole badge is attached, the sole bottom surface 325 may be configured with a recess to receive the sole badge.

[0120] The multi-component putter body 300 further comprises at least one aperture 308, which when coupled with a toe mass 321 and a heel mass 322, allows for more extreme perimeter weighting, resulting in increased forgiveness. The at least one aperture 308 must extend through both the crown component 310 and the sole component 320, such that the at least one aperture 308 is a through hole. Generally, the at least one aperture 308 is located near a central location of the body 300, which removes weight from this region to be concentrated at the perimeter. In some embodiments, the body 300 comprises a heel aperture 308a and a toe aperture 308b. The heel aperture 308a is defined by a heel perimeter rail 318, a central bar 314 extending from the strike face 307 to the rear 304, and a front heel wing 334 which connects the central bar 314 to the heel perimeter rail 318. The toe aperture 308b is defined by a toe perimeter rail 316, the central bar 314, and a front toe wing 335 which connects the central bar 314 to the toe perimeter rail 318. The heel aperture 308a and the toe aperture 308b increase the moment of inertia of the putter head by increasing the perimeter weighting. While this embodiment is discussed separately from the multi-component putter 100, 200 disclosed herein, it should be appreciated that features of the multi-component putter 100, 200 can be incorporated into any of the embodiments of the multi-component putter 300 to provide a putter that both has adjustable weighting and can adjust a resting face angle.

[0121] The heel perimeter rail 318 extends from the rear portion of the central bar 314 to the front heel wing 334. Similarly, the toe perimeter rail 316 extends from the rear portion of the central bar 314 to the front toe wing 335. The heel perimeter rail 318 and the toe perimeter rail 316 connect the front heel wing 334 and the front toe wing 335 with the central bar 314, respectively. These components of the body 300 create three discrete surfaces on the heel 303, a central bar inner heel surface 315a, a heel rail inner surface 319, and a front heel wing inner surface 336. Additionally, the components of the body 300 also create three discrete surfaces on the toe 302, a central bar inner toe surface 315b, a toe rail inner surface 317, and a front toe wing inner surface 337. These inner surfaces have a crown to sole height and surround/define the at least one aperture 308 extending through the body 300. Generally, the at least one aperture 308 can be formed through machining through the body 300 or removing material through a stamping or forging step.

[0122] Each of the central bar inner heel surface 315a, central bar inner toe surface 315b, heel rail inner surface 319, toe rail inner surface 317, front heel wing inner surface 336, and front toe wing inner surface 337 extend from the crown to the sole of the putter. These surfaces may be formed by either the crown component 310, sole component 320, or portions of both the crown component 310 and sole component 320.

[0123] As described previously, the multi-component putter body 300 may comprise a split plane 350 with a split plane angle 350 that aids in obscuring the sole component 320 from address. The split plane 350 is a plane that intersects the region where the draft angle of the outer surface changes. For instance, below the split plane 350, the body 300 is drafted inward, towards the sole 323 and above the split plane 350, the body is drafted inwards, towards the top. Generally, the split plane is parallel to the ground plane 1010 and the split plane angle 352 is measured from a plane 1035 perpendicular to the ground plane 1010 that abuts the point the draft angle changes. In some embodiments, the split plane angle is 7 degrees. The at least one aperture 308 may also comprise a split plane 350 with a split plane angle 352. In some embodiments, the at least one aperture split plane 350 and split plane angle 352 may match that of the perimeter of the body, but in other embodiments, split plane 350 and split plane angle 352 of the at least one aperture 308 may be different than the perimeter of the body.

[0124] The assembled putter creates a crown projection and a sole projection, which are the visible portions of the crown component 310 and sole component 320 at address. In some embodiments of the mallet-style putter with apertures, the crown projection accounts for 9.11 in.sup.2, while the sole projection accounts for 0.313 in.sup.2. It should be noted that with the addition of the at least one aperture, there is an outer and inner crown and sole projection. Specifically, the outer projections are related the perimeter of the body, while the inner projection is made up from the apertures. Overlaying the crown projection over the sole projection equates to approximately 96.7% of the address view being from the crown component 310. This promotes a large crown projection and a small sole projection, which again allows for a premium aesthetic that is non-distracting to the user. The split plane 150 and split plane angle 152 act to produce this desirable aesthetic.

[0125] 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.

[0126] 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.

EXAMPLES

I. Example 1: Comparison of Volume Phase Percentage in Three Exemplary Multi-Component Putter Head Samples

[0127] The purpose of this example is to demonstrate the difference in volume phase percentage in the material of a multi-component putter head based on the manufacturing process. An image analysis was performed following the ASTM E1245-03 (2023), known as the Standard Practice for Determining the Inclusion or Second-Phase Constituent Content of Metals by Automatic Image Analysis to determine the phase percentage of each sample. Three aluminum putter head samples, created with different manufacturing processes, were tested. A first sample (hereafter ATS #1) consisted of an AC12 cast putter head, a second sample (hereafter ATS #2) consisted of a 6061 bar putter head, and a third sample (hereafter ATS #3) consisted of a 6061 forged putter head made from billet.

[0128] To perform the image analysis, each of the samples were sectioned approximately one inch behind the striking surface. A small section of the sample was removed and metallographically polished to examine the microstructure, this is referred to as the longitudinal direction. An additional sample taken perpendicular to the surface and was also metallographically polished to examine the microstructure, this is referred to as the transverse direction.

TABLE-US-00001 TABLE I Volume Phase Percentage Results Phase Percentage, % Sample Direction Aluminum Inclusions ATS #1 (Cast) Transverse 61.0 39.0 Longitudinal 54.6 45.4 ATS #2 (Milled) Transverse 98.9 1.1 Longitudinal 99.0 1.0 ATS #3 (Forged) Transverse 98.4 1.6 Longitudinal 98.7 1.3

[0129] As shown in Table I, the results exhibit a significant degree of variance across the different samples. ATS #1 comprised a 61% of aluminum and 39% of inclusions in the transverse direction, and 54.5% of aluminum and 45.4% of inclusions in the longitudinal direction. The micrographs of the microstructure of ATS #1 in the longitudinal direction can be observed in FIG. 21, and in the transverse direction can be observed in FIG. 22. The results indicate that this sample exhibits a higher phase percentage covered by inclusions. These inclusions form when the flow agents used during the die-casting process react with aluminum, resulting in impurities within the material. The presence of inclusions is highly undesirable, as it directly impacts the material's mechanical properties, manufacturability, and overall performance. Inclusions can serve as stress concentrators, introduce structural weaknesses within the metal, and contribute to defects during manufacturing processes, leading to increased tool wear and inconsistent material behavior. As, well, for the purpose of the claimed invention, die cast putters cannot be anodized, as the final product does not comprise pure aluminum (>98%).

[0130] ATS #2 comprised 98.9% of aluminum and 1.1% of inclusions in the transverse direction, and 99.0% of aluminum and 1.0% of inclusions in the longitudinal direction. The micrograph of the microstructure of ATS #2 in the longitudinal direction can be observed in FIG. 23, and in the transverse direction can be observed in FIG. 24. Since machining aluminum is a subtractive manufacturing process, it does not involve melting or the introduction of additional substances that could react with the material. As a result, it effectively prevents oxidation, contamination, and alloy segregation. Conversely, machining incurs higher costs and is subject to limitations in terms of orientation, cutting path, and time.

[0131] ATS #3 comprised 98.4% of aluminum and 1.6% of inclusions in the transverse direction, and 98.7% of aluminum and 1.3% of inclusions in the longitudinal direction. The micrograph of the microstructure of ATS #2 in the longitudinal direction can be observed in FIG. 25, and in the transverse direction can be observed in FIG. 26. Since forming aluminum does not rely on molten metal, means there is less chance of trapping gases, non-metallic inclusions, or impurities that could dilute the aluminum concentration, allowing the product to maintain elevated levels of aluminum concentration.

[0132] Consequently, this example illustrates that both forging and machining are preferable manufacturing processes compared to die casting. While both of these processes are favorable, forging aluminum can present better benefits in comparison to machining aluminum. Forging aluminum can refine the grain structure of the aluminum, which thereby can improve its fatigue resistance, strength, and toughness, while machining simply removes material without enhancing these properties. On the other hand, based on the claimed invention, forging can also produce complex shapes, while reducing the need for extensive machining. As well as efficiently saving time as well as reducing manufacturing cost, in comparison for time consuming extensive machining, as well as the cost of machining aluminum.

II. Example 2: Porosity Results in Three Exemplary Multi-Component Putter Head Samples

[0133] The purpose of this example is to demonstrate the difference in porosity in the material of a multi-component putter head based on the manufacturing process. An image analysis was performed following the ASTM E1245-03 (2023), known as the Standard Practice for Determining the Inclusion or Second-Phase Constituent Content of Metals by Automatic Image Analysis to determine the porosity percentage of each sample. Three aluminum putter head samples with different manufacturing processes were used to perform the test. A first sample (hereafter ATS #1) consisted of an AC12 cast putter head, a second sample (hereafter ATS #2) consisted of a 6061 bar putter head, and a third sample (hereafter ATS #3) consisted of a 6061 forged putter head made from billet.

TABLE-US-00002 TABLE II Porosity Results Sample Porosity Percentage ATS #1 (Cast) 2.9% ATS #2 (Milled) Not present ATS #3 (Forged) Not present

[0134] As observed in Table II, ATS #1 was the only sample that exhibited a measurable percentage of porosity, while samples ATS #2 and ATS #3 did not exhibit a measurable percentage of porosity. As described above, ATS #1 sample comprises the aluminum head that was die cast. Die casting employs rapid injection of molten metal into a mold, which can result in the entrapment of air within the aluminum components. This can lead to the formation of small voids 460, referred to as porosity, illustrated in FIG. 22. For optimal results, the porosity percentage is expected to be at least below 1%, as anything over 1% presents a non-desirable result. Porosity introduces weak points within the material, compromising its structural integrity and increasing the likelihood of failure under stress.

III. Example 3: Forged Multi-Component Putter Vs. Cast Multi-Component Putter

[0135] Comparing two multi-component putters, wherein a Sample A is a spade-shaped mallet putter with a forged aluminum crown component consistent with the current disclosure and Sample B is a spade-shaped mallet putter with a cast crown component. Sample A comprised a crown projection that covered approximately 99.7% of the total body projection. Therefore 0.3% of the total body projection at address is from the sole projection. Sample B comprised a crown projection of approximately 60% of the total body projection. Therefore, 40% of the sole projection is visible from an address view. Having a larger crown projection provides a more unitary and premium aesthetic.

CLAUSES

[0136] Clause 1. A putter-type golf club head comprising a sole component formed of a sole component material having a sole component material density, the sole component including a sole bottom surface defining at least a portion of a sole of the putter-type golf club head, a sole top surface, a sole projection from a top plan view, the sole projection having a sole projection border that defines a sole projection area, and a crown component formed of a crown component material different from the sole component material and having a crown component material density less than the sole component material density, the crown component including a crown bottom surface coupled to the sole top surface, a crown top surface defining at least a portion of a crown of the putter-type golf club head, a crown projection from the top plan view, the crown projection having a crown projection border that defines a crown projection area, wherein the crown projection area encompasses at least 95% of the sole projection area such that no more than 5% of the sole component is visible from the top plan view, the crown component material comprises a crown component forged material including at least 98.9% aluminum, and the sole component comprises at least 70% of a total weight of the putter-type golf club head.

[0137] Clause 2. The putter-type golf club head of clause 1, wherein the crown component further comprises an anodized layer forming the crown top surface.

[0138] Clause 3. The putter-type golf club head of clause 2, wherein the anodized layer comprises a first color.

[0139] Clause 4. The putter-type golf club head of clause 3, wherein the anodized layer further comprises a second color different than the first color.

[0140] Clause 5. The putter-type golf club head of clause 4, wherein the second color forms a second color pattern arranged as an alignment feature.

[0141] Clause 6. The putter-type golf club head of clause 1, wherein the crown component forged material has a porosity of less than 2.9%.

[0142] Clause 7. The putter-type golf club head of clause 1, further comprising a putter head height extending from a ground plane to a top point of a top rail in a direction perpendicular to the ground plane, a putter head maximum perimeter associated with a maximum projected perimeter area from the top plan view, and a split plane parallel to the ground plane and coincident with the putter head maximum perimeter, wherein the split plane is at least 60% of the putter head height above the ground plane.

[0143] Clause 8. The putter-type golf club head of clause 7, wherein the sole component and the crown component define an overall putter side surface that includes a side surface lower region below the split plane and extending inwardly from the putter head maximum perimeter at a lower region draft angle, and a side surface upper region above the split plane and extending inwardly from the putter head maximum perimeter at an upper region draft angle.

[0144] Clause 9. The putter-type golf club head of clause 8, wherein each of the lower region draft angle and the upper region draft angle is 7 degrees.

[0145] Clause 10. The putter-type golf club head of clause 1, wherein the crown component and the sole component comprise at least one aperture.

[0146] Clause 11. A putter-type golf club head comprising a body comprising a strike face, a sole component made of a first material contributing at least 85% of the total body weight, the sole component further comprising a sole extending rearward from a bottom of the strike face and having a sole lower surface and a sole upper top surface, a top rail extending rearward from a top of the strike face and including a lip projecting over the sole upper top surface, a rear wall joining the sole upper top surface to the lip of the top rail and defining a rear wall cavity open to a rear of the club, and a crown component made of a second material, coupled to the sole component, the crown component comprising a crown component front wall disposed in the rear wall cavity of the body, a crown component rear extension overlaying the sole upper top surface of the body, wherein the lip of the top rail extends over an entirety of the crown component front wall, wherein the first material is denser than the second material, and wherein the second material is at least 98.9% pure aluminum.

[0147] Clause 12. The putter-type golf club head of clause 11, wherein the lip defines a lip rear edge located rearward of the crown component front wall and extends from a top end of the body to a heel end of the body.

[0148] Clause 13. The putter-type golf club head of clause 12, wherein the lip rear edge is linear.

[0149] Clause 14. The putter-type golf club head of clause 11, wherein the sole comprises a sole recess.

[0150] Clause 15. The putter-type golf club head of clause 14, wherein the sole recess is configured to receive a sole badge.

[0151] Clause 16. The putter-type golf club head of clause 11, wherein the crown component further comprises an anodized layer forming the crown top surface.

[0152] Clause 17. The putter-type golf club head of clause 16, wherein the anodized layer comprises a first color.

[0153] Clause 18. The putter-type golf club head of clause 17, wherein the anodized layer further comprises a second color different than the first color.

[0154] Clause 19. The putter-type golf club head of clause 11, wherein the second material forming the crown component forged material has a porosity of less than 2.9%.

[0155] Clause 20. The putter-type golf club head of clause 11, wherein the strike face comprises a strike face insert.