Co-forged golf club head and method of manufacture

Abstract

A co-forged iron type golf club is disclosed. More specifically, the present invention discloses a co-forged iron type golf club with the body portion made out of a first material and at least one weight adjustment portion monolithically encased within the body portion of the co-forged iron type golf club head without the need for secondary attachment or machining operations. The present invention creates of an iron type golf club head from a pre-form billet that already contains two or more materials before the actual forging process resulting in a multi-material golf club head that doesn't require any post manufacturing operations such as machining, welding, swaging, gluing, and the like.

What is claimed is: 
     
         1 . A forged golf club head comprising:
 a body portion, made out of a first material having a first density, defining at least one cavity;   at least one weight adjustment portion, made out of a second material having a second density, adapted to engage said at least one cavity; and   a cap, made out of a third material having a third density, at least partially enclosing said cavity;   wherein said at least one weight adjustment portion is encased monolithically within said body portion,   wherein an outer surface area of said at least one weight adjustment portion equals an inner surface area of said at least one cavity, and   wherein said third material is different from said first material.   
     
     
         2 . The forged golf club head of  claim 1 , wherein said third density is greater than said first density. 
     
     
         3 . The forged golf club head of  claim 2 , wherein said second density is greater than said third density. 
     
     
         4 . The forged golf club head of  claim 1 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Fe-17.5W-0.5Si. 
     
     
         5 . The forged golf club head of  claim 1 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Fe-20W-1.0Si. 
     
     
         6 . The forged golf club head of  claim 1 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Fe-26W-0.5Si. 
     
     
         7 . The forged golf club head of  claim 1 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Cu-14W-0.5Si. 
     
     
         8 . The forged golf club head of  claim 1 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Cu-16.5W-1.0Si. 
     
     
         9 . The forged golf club head of  claim 1 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Cu-23W-0.5Si. 
     
     
         10 . A method of forging a golf club head comprising:
 forging a cylindrical billet out of a first material to create a body portion of said golf club head, wherein said body portion of said golf club head comprises one or more cavities;   at least partially filling said one or more cavities with a second material to create a weight adjustment portion;   providing a cap made out of a third material to at least partially encase said weight adjustment portion within said one or more cavities;   forging said body portion of said golf club head containing said weight adjustment portion to create said golf club head;   wherein said third material is different from said first material.   
     
     
         11 . The method of forging a golf club head of  claim 10 , wherein said third material has a third density and said first material has a first density, said third density is greater than said first density. 
     
     
         12 . The method of forging a golf club head of  claim 11 , wherein said second material has a second density, and said second density is greater than said third density 
     
     
         13 . The method of forging a golf club head of  claim 10 , wherein said third material is a nickel based alloy having a chemical composition of Ni-15Fe-17.5W-0.5Si. 
     
     
         14 . A golf club head comprising:
 a body portion, made out of a first material having a first density, defining at least one cavity and at least one face cavity;   at least one weight adjustment portion, made out of a second material having a second density, adapted to engage said at least one cavity; and   a striking face insert, made out of two or more materials, adapted to cover said face cavity;   wherein said weight adjustment portion is encased monolithically within said body portion, and   wherein said striking face insert is formed using a co-forged method.   
     
     
         15 . The golf club head of  claim 14 , wherein said striking face insert further comprises a fourth material and a fifth material,
 wherein said a perimeter of said fourth material is encompassed by said fifth material, and   wherein said fourth material and said fifth material are different from each other.   
     
     
         16 . The golf club head of  claim 15 , wherein a density of said fourth material is lower than a density of said fifth material. 
     
     
         17 . The golf club head of  claim 16 , wherein a rear surface of said striking face insert further comprises a plurality of horizontal cutouts. 
     
     
         18 . The golf club head of  claim 16 , wherein an entirely of a rear surface of said striking face insert is removed.