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 at least one weight cavity;   a lightweight weight adjustment portion comprising 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 third material is a non-metallic material which is rigid and non-granular, and   wherein said at least one high density weight adjustment portion is encased monolithically within said at least one 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 lightweight weight adjustment portion further comprises a loose powder type material. 
     
     
         6 . The forged golf club head of  claim 2 , wherein said lightweight weight adjustment portion is substantially the same shape as said striking face insert. 
     
     
         7 . The forged golf club head of  claim 2 , wherein said lightweight weight adjustment portion contains at least one cutout. 
     
     
         8 . The forged golf club head of  claim 2 , wherein said lightweight weight adjustment portion contains a plurality of cutouts. 
     
     
         9 . The forged golf club head of  claim 2 , wherein said at least one high density weight adjustment portion is located near a sole of said golf club head. 
     
     
         10 . The forged golf club head of  claim 9 , wherein said at least one high density weight adjustment portion is located near a heel portion of said sole of said golf club head. 
     
     
         11 . The forged golf club head of  claim 9 , wherein said at least one high density weight adjustment portion is located near a toe portion of said sole of said golf club head. 
     
     
         12 . 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 at least one weight cavity;   a lightweight weight adjustment portion made out of 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,   wherein said lightweight weight adjustment portion contains at least one cutout, and   wherein said at least one high density weight adjustment portion is encased monolithically within said at least one weight 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 non-metallic material is a glass material. 
     
     
         15 . The forged golf club head of  claim 13 , wherein said non-metallic material is a ceramic material. 
     
     
         16 . The forged golf club head of  claim 13 , 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. 
     
     
         17 . The forged golf club head of  claim 13 , wherein said lightweight weight adjustment portion contains a plurality of cutouts. 
     
     
         18 . The forged golf club head of  claim 13 , wherein said lightweight weight adjustment portion further comprises a loose powder type material. 
     
     
         19 . The forged golf club head of  claim 13 , wherein said at least one high density weight adjustment portion is located near a sole of said golf club head. 
     
     
         20 . The forged golf club head of  claim 19 , wherein said at least one high density weight adjustment portion is located near a toe portion of said sole of said golf club head.