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 also includes a combination of lightweight and heavy density weight adjustment portions that could be introduced towards the final forging step of the co-forging process, allowing for more flexibility in the selection of materials.

What is claimed is: 
     
         1 . A forged golf club head comprising:
 a body portion made out of a first material having a face cavity and at least one weight cavity;   at least one high density weight adjustment portion made out of a second material encased within said weight cavity;   a lightweight weight adjustment portion made out a third material encased within said face cavity; and   a striking face insert made out of said first material adapted to cover said face cavity,   wherein said lightweight weight adjustment portion is a non-metallic material, and   wherein said high density weight adjustment portion is encased monolithically within said weight cavity.   
     
     
         2 . 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. 
     
     
         3 . The forged golf club head of  claim 2 , wherein said non-metallic material is a glass material. 
     
     
         4 . The forged golf club head of  claim 2 , wherein said non-metallic material is a ceramic material. 
     
     
         5 . The forged golf club head of  claim 2 , wherein said non-metallic material is a loose powder type material. 
     
     
         6 . The forged golf club head of  claim 3 , wherein said at least one weight adjustment portion is located near a sole of said golf club head. 
     
     
         7 . The forged golf club head of  claim 6 , wherein said at least one weight adjustment portion is located near a heel portion of said sole of said golf club head. 
     
     
         8 . The forged golf club head of  claim 7 , wherein said at least one weight adjustment portion is located near a toe portion of said sole of said golf club head. 
     
     
         9 . A forged golf club head comprising:
 a body portion made out of a first material having a lightweight cavity and at least one weight cavity,
 wherein said lightweight cavity is located at an upper blade portion of said body portion; 
   at least one high density weight adjustment portion made out of a second material encased within said weight cavity;   a lightweight weight adjustment portion made out a third material encased within said lightweight cavity; and   a striking face insert made out of said first material adapted to cover said lightweight cavity,   wherein said lightweight weight adjustment portion is a non-metallic material, and   wherein said high density weight adjustment portion is encased monolithically within said weight cavity.   
     
     
         10 . The forged golf club head of  claim 9 , 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. 
     
     
         11 . The forged golf club head of  claim 10 , wherein said non-metallic material is a glass material. 
     
     
         12 . The forged golf club head of  claim 10 , wherein said non-metallic material is a ceramic material. 
     
     
         13 . The forged golf club head of  claim 10 , wherein said non-metallic material is a loose powder type material. 
     
     
         14 . The forged golf club head of  claim 10 , wherein said non-metallic material is a combination of at least two of the following: a glass material, a ceramic material, and a loose powder type material. 
     
     
         15 . The forged golf club head of  claim 10 , wherein said at least one weight adjustment portion is located near a sole of said golf club head. 
     
     
         16 . A method of forging a golf club head comprising:
 begin by pre-forging a cylindrical billet to create a body portion with a first material, comprising at least one lightweight cavity and one or more weight cavities into said body portion,   at least partially filling said one or more weight cavities with a second material to create a high density weight adjustment portion;
 providing a cap to at least partially encase said high density weight adjustment portion within said one or more weight cavities; 
   at least partially filling said at least one lightweight cavity with a non-metallic material to create a lightweight weight adjustment portion,
 providing a striking face insert to completely encase said lightweight weight adjustment portion within said lightweight cavity, 
   finalize by post-forging said body portion containing said lightweight weight adjustment portion and said high density weight adjustment portion to create said golf club head,   wherein said high density weight adjustment portion is encased within said body portion, and   wherein said second material has a higher density than said first material.   
     
     
         17 . The method of  claim 16 , wherein said non-metallic material is a glass material. 
     
     
         18 . The method of  claim 16 , wherein said non-metallic material is a ceramic material. 
     
     
         19 . The method of  claim 16 , wherein said non-metallic material is a loose powder type material.