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 final 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 at least one deep face cavity and at least one shallow face cavity;   at least one high density weight adjustment portion made out of second material adapted to engage at least one of said at least one deep face cavity or said at least one shallow face cavity;   a lightweight weight adjustment portion made out of a third material adapted to engage at least one of said at least one deep face cavity or said at least one shallow face cavity; and   a striking face insert made out of said first material adapted to cover a frontal portion of said body portion,   wherein both said at least one deep face cavity and said at least one shallow face cavity have an opening towards a frontal portion of said golf club head such that said striking face insert completely covers both said at least one deep face cavity and said at least one shallow face cavity, and   wherein none of said at least one lightweight weight adjustment portions are placed more toe-ward than any of said at least one high density weight adjustment portion.   
     
     
         2 . The forged golf club head of  claim 1 , wherein none of said at least one shallow face cavity is located lower on said face than any of said at least one deep face cavity. 
     
     
         3 . The forged golf club head of  claim 2 , wherein said body portion comprises a lower heel deep face cavity, a lower toe deep face cavity, and an upper shallow face cavity,
 wherein said lower heel deep face cavity is filled with said lightweight weight adjustment portion,   wherein said lower toe deep face cavity is filled with said high density weight adjustment portion, and   wherein said upper shallow face cavity is filled with said lightweight weight adjustment portion.   
     
     
         4 . The forged golf club head of  claim 2 , wherein said body portion further comprises a lower heel deep face cavity, a lower toe deep face cavity, an upper heel shallow face cavity, and a upper toe shallow face cavity,
 wherein said lower heel deep face cavity is filled with said lightweight weight adjustment portion,   wherein said lower toe deep face cavity is filled with said high density weight adjustment portion,   wherein said upper heel shallow face cavity is filled with said lightweight weight adjustment portion, and   wherein said upper toe shallow face cavity is filled with said high density weight adjustment portion.   
     
     
         5 . The forged golf club head of  claim 2 , wherein said body portion further comprises a lower deep face cavity, an upper heel shallow face cavity, and a upper toe shallow face cavity,
 wherein said lower deep face cavity is filled with said lightweight weight adjustment portion,   wherein said upper heel shallow face cavity is filled with said lightweight weight adjustment portion, and   wherein said upper toe shallow face cavity is filled with said high density weight adjustment portion.   
     
     
         6 . The forged golf club head of  claim 1 , wherein a density of said second material is greater than a density of said first material, and wherein said density of said first material is greater than a density of said third material. 
     
     
         7 . The forged golf club head of  claim 1 , wherein said lightweight weight adjustment portion further comprises a plurality of two or more cutouts; and either a rear surface of said striking face insert or a frontal surface of said at least one shallow face cavity further comprises a plurality of posts; said plurality of posts adapted to engage said plurality of two or more cutouts. 
     
     
         8 . The forged golf club head of  claim 7 , wherein only said rear surface of said striking face insert further comprises said plurality of posts. 
     
     
         9 . The forged golf club head of  claim 7 , wherein only said frontal surface of said at least one shallow face cavity further comprises said plurality of posts. 
     
     
         10 . The forged golf club head of  claim 7 , wherein both said rear surface of said striking face insert and said frontal surface of said at least one shallow face cavity further comprises said plurality of posts. 
     
     
         11 . The forged golf club head of  claim 7 , wherein said plurality of two or more cutouts are evenly distributed across an entirety of said lightweight weight adjustment portion. 
     
     
         12 . A forged golf club head comprising:
 a body portion made out of a first material having at least one deep face cavity and at least one shallow face cavity;   at least one high density weight adjustment portion made out of second material adapted to engage at least one of said at least one deep face cavity or said at least one shallow face cavity;   a lightweight weight adjustment portion made out of a third material adapted to engage at least one of said at least one deep face cavity or said at least one shallow face cavity; and   a striking face insert made out of said first material adapted to cover a frontal portion of said body portion,   wherein both said at least one deep face cavity and said at least one shallow face cavity have an opening towards a frontal portion of said golf club head such that said striking face insert completely covers both said at least one deep face cavity and said at least one shallow face cavity, and   wherein none of said at least one shallow face cavity is located lower on said face than any of said at least one deep face cavity.   
     
     
         13 . The forged golf club head of  claim 12 , wherein a density of said second material is greater than a density of said first material, and wherein said density of said first material is greater than a density of said third material. 
     
     
         14 . The forged golf club head of  claim 13 , wherein said body portion comprises a lower heel deep face cavity, a lower toe deep face cavity, and an upper shallow face cavity,
 wherein said lower heel deep face cavity is filled with said lightweight weight adjustment portion,   wherein said lower toe deep face cavity is filled with said high density weight adjustment portion, and   wherein said upper shallow face cavity is filled with said lightweight weight adjustment portion.   
     
     
         15 . The forged golf club head of  claim 13 , wherein said body portion further comprises a lower heel deep face cavity, a lower toe deep face cavity, an upper heel shallow face cavity, and a upper toe shallow face cavity,
 wherein said lower heel deep face cavity is filled with said lightweight weight adjustment portion,   wherein said lower toe deep face cavity is filled with said high density weight adjustment portion,   wherein said upper heel shallow face cavity is filled with said lightweight weight adjustment portion, and   wherein said upper toe shallow face cavity is filled with said high density weight adjustment portion.   
     
     
         16 . The forged golf club head of  claim 13 , wherein said body portion further comprises a lower deep face cavity, an upper heel shallow face cavity, and a upper toe shallow face cavity,
 wherein said lower deep face cavity is filled with said lightweight weight adjustment portion,   wherein said upper heel shallow face cavity is filled with said lightweight weight adjustment portion, and   wherein said upper toe shallow face cavity is filled with said high density weight adjustment portion.