Forged iron head

Abstract

There is a need in this field for an iron-type golf club head that has an improved mass distribution for improved inertia, while also maintaining the aesthetic appearance of a full muscle-back iron. [Solution] The iron-type golf club head 100 comprises a main club head body, a lightweight weight 430, a back cavity insert, a void 710 within the lightweight weight, and a lightweight back cavity insert configured to accept a CTP weight that can adjust the mass characteristics of the iron-type golf club head.

Description

Technical Field

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[0001] Cross - Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 62 / 839,411, filed Apr. 26, 2019.

[0002] The present disclosure generally relates to a golf club head having a 3D forged lightweight part within a back cavity.

Background Art

[0003] There is a need in the art for an iron - type golf club head that has an improved mass distribution for improved inertia while maintaining the aesthetics of a complete muscle - back iron. ​​​​​​​​​​​​​​​​​​​​​​​​​​This shows an iron-type golf club head having contact surfaces for upper and lower forging dies and a billet of lightweight material.

[0009] [Figure 3B] The diagram shows an iron-type golf club head with contact surfaces for upper and lower forging dies, a billet of lightweight material, and a forging rod used to create voids in the lightweight material.

[0010] [Figure 4A] An exploded view of an iron-type golf club head is shown.

[0011] [Figure 4B] An exploded view of an iron-type golf club head is shown.

[0012] [Figure 4C] An exploded view of an iron-type golf club head is shown.

[0013] [Figure 5A] This shows the main club body and lightweight back cavity insert of an iron-type golf club head.

[0014] [Figure 5B] This is a bottom cross-sectional view showing the void inside the lightweight back cavity insert.

[0015] [Figure 6] This shows a lightweight back cavity insert.

[0016] [Figure 7A] This shows an iron-type golf club head with a void inside a lightweight back cavity insert.

[0017] [Figure 7B] This shows an iron-type golf club head with a weight inside a void.

[0018] [Figure 8] Indicates the CTP weight.

[0019] [Figure 9] Discloses a method of forming a golf club head.

[0020] [Figure 10] Discloses a method of forming a golf club head.

[0021] [Figure 11] Discloses a method of forming a golf club head.

[0022] Figures 1 - 9 illustrate a single embodiment of an iron-type golf club head.

[0023] Other aspects of the present disclosure will become apparent upon consideration of the detailed description and the accompanying drawings.

Best Mode for Carrying Out the Invention

[0024] The iron-type golf club described herein provides both the visual aesthetics of a conventional muscle-back iron-type golf club head and the mass characteristics of a more forgiving cavity-back iron-type golf club head and the ability to adjust the club head center of gravity provided by a removable CTP weight. The iron-type golf club head includes a back cavity that allows more mass to be moved to the outer perimeter of the golf club head. A lightweight back cavity component or lightweight component is attached within the back cavity. The golf club head further includes a CTP weight that is received along with voids within the lightweight component that allow for changes in mass characteristics by configuring the mass of the CTP weight.

[0025] Wherever terms such as “first,” “second,” “third,” “fourth,” etc., appear in the specification and claims, they are used to distinguish similar parts and not necessarily to describe a specific order or chronological order. Terms used in this way are interchangeable under appropriate circumstances. For example, embodiments described herein may operate in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “includes,” “having,” and any variations thereof may include other parts not expressly described or inherent in such a process, method, system, article, device, or apparatus, although such a list of parts is not necessarily limited to those parts.

[0026] Terms such as “left,” “right,” “front,” “rear,” “top,” “bottom,” “up,” and “down” in the specification and claims are used for descriptive purposes, if any, and are not necessarily used to describe permanent relative positions. It should be understood that such terms are interchangeable under appropriate circumstances so that embodiments of the apparatus, methods, and / or articles described herein may operate in orientations other than those illustrated or otherwise described herein.

[0027] Before any embodiment of this disclosure is described in detail, it should be understood that this disclosure is not limited in the application to the configuration details and component arrangements described in the following description or illustrated in the following drawings. Other embodiments of this disclosure are possible and can be implemented or performed in a variety of ways.

[0028] The golf club configurations described herein may apply to one or more golf clubs within an iron set. In embodiments, a set of irons may include irons having variable club head size, shaft length, lie angle, loft angle, head weight, and / or other parameters. Each club head in an iron set may be numbered according to convention, ranging from 1 to 10. Most commonly, sets are numbered 2 through 9, with wedges and utility clubs. Furthermore, an iron set may include one or more wedges having a higher loft angle than the numbered irons.

[0029] In some embodiments, the golf club head 100 may be a wedge. In many embodiments, the loft angle of the golf club head 100 is less than approximately 50 degrees, less than approximately 49 degrees, less than approximately 48 degrees, less than approximately 47 degrees, less than approximately 46 degrees, less than approximately 45 degrees, less than approximately 44 degrees, less than approximately 43 degrees, less than approximately 42 degrees, less than approximately 41 degrees, or less than approximately 40 degrees. Furthermore, in many embodiments, the loft angle of the golf club head 100 is greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

[0030] In many embodiments, the loft angle of the golf club head is less than approximately 64 degrees, less than approximately 63 degrees, less than approximately 62 degrees, less than approximately 61 degrees, less than approximately 60 degrees, less than approximately 59 degrees, less than approximately 58 degrees, less than approximately 57 degrees, less than approximately 56 degrees, less than approximately 55 degrees, or less than approximately 54 degrees. Furthermore, in many embodiments, the loft angle of the golf club head is greater than approximately 46 degrees, greater than approximately 47 degrees, greater than approximately 48 degrees, greater than approximately 49 degrees, greater than approximately 50 degrees, greater than approximately 51 degrees, or greater than approximately 52 degrees.

[0031] In many embodiments, the golf club head may have a total volume of 1.9 cubic inches to 2.7 cubic inches. In some embodiments, the total volume of the golf club head may be 1.9 cubic inches to 2.4 cubic inches, 2.0 cubic inches to 2.5 cubic inches, 2.1 cubic inches to 2.6 cubic inches, 2.2 cubic inches to 2.7 cubic inches, 2.3 cubic inches to 2.7 cubic inches, or 2.4 cubic inches to 2.7 cubic inches. In other embodiments, the total volume of the golf club head may be 1.9 cubic inches, 2.0 cubic inches, 2.1 cubic inches, 2.2 cubic inches, 2.3 cubic inches, 2.4 cubic inches, 2.5 cubic inches, 2.6 cubic inches, or 2.7 cubic inches.

[0032] In many embodiments, the golf club head may contain a total mass of 200 to 300 grams. In some embodiments, the golf club head may contain a total mass of 200 to 210 grams, 210 to 220 grams, 220 to 230 grams, 230 to 240 grams, 240 to 250 grams, 250 to 260 grams, 255 to 260 grams, 260 to 270 grams, 265 to 275 grams, 270 to 280 grams, 275 grams, and 280 grams, or 250 to 270 grams. In other embodiments, the total mass can be 200 grams, 205 grams, 210 grams, 220 grams, 225 grams, 230 grams, 235 grams, 240 grams, 245 grams, 250 grams, 255 grams, 260 grams, 265 grams, 270 grams, 275 grams, 280 grams, 285 grams, 290 grams, 295 grams, or 300 grams.

[0033] Main body of a golf club head Iron-type golf club heads feature a body with a back cavity that allows for the movement of more mass to the periphery of the golf club head. A lightweight back cavity component or lightweight insert is fitted within the back cavity. The golf club head further includes a CTP weight that is received with a gap within the lightweight component, and by constituting the mass of the CTP weight, it is possible to change the mass characteristics by shifting the center of gravity of the golf club head toward the toe or heel.

[0034] Referring to Figures 1 and 2, the body 410 of the iron-type golf club head 100 has a toe end 110, a heel end, a front part having a strike surface 140 for impacting a golf ball, a hosel, a top rail 120, a sole, a hosel configured to receive the shaft, a rear part opposite the front part, a back cavity 220 enclosed and defined by the rear surface 230 of the strike surface 140, and an outer peripheral side wall 460. The outer peripheral side wall 460 encloses the back cavity 220 formed by the top rail 120, the sole 150, the toe end 110, and the heel end 130. The sole 150 of the body 410 extends further towards the rear of the body 410 than the top rail 120. Therefore, the lower part of the outer peripheral side wall 460 extends further towards the rear than the upper part of the outer peripheral side wall 460. The back cavity 220 has depth, and the depth of the back cavity 220 is greater at the bottom, in the soleward portion, than at the top, in the top rail 120 portion.

[0035] Figures 1, 2, and 4A through 8 all show a single embodiment of the golf club head 100. All numbered features and parts are features and parts of the golf club head 100. Figures 3A and 3B also have parts that share these parts but are related to the manufacturing method.

[0036] Referring to Figure 1, the club head 100 defines a ground surface 1000 that contacts the sole 150 when the club head 100 is in the address position.

[0037] Referring to Figures 2 and 4A, the outer peripheral wall 460 is substantially perpendicular to the rear surface 230. The outer peripheral wall 460 may deviate from the perpendicular by plus or minus 5 degrees. The heel end 130 of the golf club head 100 may have an opening 210 passing through the heel end 130, so that the opening 210 opens to the outer surface of the heel end 130 and opens to the back cavity 220.

[0038] Referring to Figures 2 and 4A, the outer peripheral wall 460 includes a locking groove 240 within the outer peripheral wall 460 along the periphery of the back cavity 220. The locking groove 240 is recessed within the outer peripheral wall 460 surrounding the rear surface 230. The locking groove 240 is embedded within the outer peripheral wall 460 in a direction parallel to the rear surface 230 of the strike surface 140 (see Figure 2).

[0039] Referring to Figure 2, the lock groove 240 comprises a lock groove bottom and two lock groove side walls. This lock groove opens into the back cavity 220 of the body 410 before the back cavity 220 accepts the lightweight insert 430. The lock groove 240 can define a plane, where the plane intersects the center of the lock groove bottom 240 around the outer peripheral side wall 460, and the plane is essentially parallel to the strike surface 140.

[0040] Referring further to Figure 2, the lock groove 240 may have a single constant depth. In other embodiments, the depth of the lock groove 240 may vary. The lock groove 240 may have a single constant width. In other embodiments, the width of the lock groove 240 may vary. The lock groove 240 may be continuous around all of the outer peripheral side walls 460. The lock groove 240 may be discontinuous and may form multiple portions separated from each other around the outer peripheral side walls 460. The lock groove 240 may have a projection or recess along the bottom of the lock 240. The side walls of the lock groove 240 may include recesses or receding edges, and these recesses or receding edges may be perpendicular to the side walls 240 (not shown) of the lock wall.

[0041] Referring further to Figure 2, the depth of the lock groove 240 may range from 0.1 inches to 0.5 inches. The depth of the lock groove 240 may be 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, or 0.5 inches. The width of the lock groove 240 may range from 0.1 inches to 0.5 inches. The width of the lock groove 240 may be 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, or 0.5 inches.

[0042] Referring to Figures 4A and 4B, the sole 150 further comprises a CTP weight groove 370. The CTP weight groove 370 includes an axis of the CTP weight groove 370 along its length. As a result, the axis of the CTP weight groove 370 is equidistant from the edge of the CTP weight groove 370 along its length from the heel end 130 of the golf club head 100 to the toe end 110 of the golf club head 100. The axis of the CTP weight groove 370 is parallel to the rear surface 230 of the strike surface 140. The axis of the central CTP weight groove 370 defines the angle with the ground surface 1000 when the golf club head is in the address position. The CTP weight groove 370 receives a portion of the length of the CTP weight 420 when the CTP weight 420 is received within the gap 710.

[0043] Furthermore, referring to Figures 4A and 4B, when the golf club head 100 is in the address position, the axial angle of the CTP weight groove 370 with respect to the ground surface 1000 may be between 0 and 30 degrees. The axial angle of the CTP weight groove 370 may be 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 degrees.

[0044] Referring further to Figures 4A and 4B, the CTP weight groove 370 has length, width, and depth of recess. The depth of the CTP weight groove 370 is measured relative to the surface of the outer peripheral sidewall 460 of the sole 150 so that the CTP weight groove 370 defines a recess in the outer peripheral sidewall 460 of the sole 150. The depth of the recess of the CTP weight groove 370 gradually decreases as it extends from the position closest to the heel end 130 of the golf club head 100 toward the toe end 110 of the golf club head. The width of the depth of the CTP weight groove 370 gradually decreases from the position closest to the heel end 130 of the golf club head toward the toe end 110 of the golf club head. The groove 370 of the CTP weight 420 tapers to the end of the toe end 110 where the depth and width of the CTP weight groove 370 are both zero. The CTP weight groove 370 further comprises a cross-sectional profile. The cross-sectional profile of the CTP weight groove 370 may be constant. Alternatively, the cross-sectional profile of the CTP weight groove 370 may gradually change from the point closest to the heel end 130 of the golf club head toward the toe end 110 of the golf club head. The cross-sectional profile of the CTP weight groove 370 may decrease from the point closest to the heel end 130 of the golf club head toward the toe end 110 of the golf club head. The cross-sectional profile of the CTP weight groove 370 may include a radius of curvature. The CTP weight groove 370 includes an edge along the point where the receding from the outer peripheral sidewall 460 of the sole 150 begins.

[0045] Referring to Figures 2 and 4B, the body 410 of the golf club head 100 further defines a hole or opening 210 in the heel end 130 of the body 410 of the golf club head 100, extending from the outer surface of the body 410 into the back cavity 220. The opening 210 includes depth and cross-sectional area. The opening 210 defines a central axis, which extends along the depth of the opening 210 through the geometric center of the opening 210 and is essentially parallel to the rear surface 230 of the strike face. In some embodiments, the opening 210 includes a circular cross-sectional shape with a radius of curvature. In other embodiments, the opening 210 includes an arbitrary geometric cross-sectional shape (see Figure 2). The opening 210 extends from the outer surface of the heel end 130 of the golf club head body 410 through the heel end 130 of the outer peripheral side wall 460.

[0046] Furthermore, referring to Figures 2 and 4B, the central axis of the opening 210 also extends parallel to the axis of the CTP weight groove 370. In one embodiment, the cross-sectional shape of the opening 210 in the heel end 130 of the golf club body 410 may be circular, the cross-sectional shape of the CTP weight groove 370 may be a circular cross-section at any position along the length of the CTP weight groove 370, and the radius of curvature of the opening 210 and the radius of curvature of the CTP weight groove 370 may be the same.

[0047] The body 410 of the golf club head 100 may include steel alloy, titanium alloy, aluminum alloy, plastic polymer, carbon fiber, composite material, thermoplastic composite material, or any other suitable material.

[0048] Lightweight parts Figures 1-9 all show a single embodiment of the golf club head 100. All numbered features and parts are features and parts of the golf club head 100.

[0049] Referring to 4A, 4B, and 4C in Figure 2, the lightweight component 430 is located within the back cavity 220 of the main body 410 and provides a clean muscle-back aesthetic. The lightweight component 430 includes an upper section 620, a lower muscle-back section 640, and a transition section 630 between the upper section 620 and the lower muscle-back section 640. The upper section 620 does not extend further rearward than the top rail 120 of the main body 410. The lower muscle-back section 640 does not extend further rearward than the sole 150 of the main body 410. The upper section 620 has a first insert thickness. The lower muscle-back section 640 defines a second insert thickness. The thickness of the second insert can be varied. The thickness of the second insert may have the maximum thickness between the sole portion of the outer peripheral sidewall 460 and the transition section 630 of the insert. The thickness of the second insert is greater than the thickness of the first insert. The transition portion 630 of the insert includes a thickness that transitions from the thickness of the first insert to the thickness of the second insert.

[0050] Referring to Figures 2, 4A, 4B, 4C, 5A, and 6, the lightweight component 430 includes a locking flange 610 configured to be received in a locking groove 240 in the outer peripheral side wall 460 of the back cavity 220, providing a mechanical lock for holding the lightweight component 430 within the back cavity 220. The lightweight component 430 surrounds a gap 710 for holding the CTP weight 420, the gap 710 being aligned with the heel opening 210 of the main body 410. The opening 210 of the main body 410 and the gap 710 of the lightweight component 430 combine to receive the CTP weight 420 (Figure 4C). The gap 710 may be located within the lower muscle back portion 640 of the lightweight component 430. No portion of the gap 710 is located within the transition portion 630 or the upper portion 620 of the lightweight component 430.

[0051] Referring to Figures 5A, 5B, and 7A, the lightweight component 430 may surround a gap 710 aligned with an opening 210 in the heel end 130 of the golf club head 100. The gap 710 has a length measured from the heel end 130 toward the toe end 110, parallel to the sole 150 and strike surface 140 of the golf club head 100, along the axis of the groove in the CTP weight 420. The gap 710 has a diameter or cross-sectional width. The gap 710 is open to the opening 210 at the heel end 130 and closes toward the toe end 110, and the gap 710 does not completely penetrate the lightweight component 430. In many embodiments, the gap 710 may be a tapered cylinder having a cross-sectional shape complementary to the shape of the heel opening 210 of the body 410 (Figure 5A). Since the cross-sectional shape of the void 710 can be tapered, the cross-section of the void 710 toward the toe end 110 is smaller than the cross-sectional section of the void 710 toward the heel end 130 of the main body 410.

[0052] The length of the gap 710 may range from 2.0 inches to 4.0 inches. The length of the gap 710 may be 2.0 inches, 2.5 inches, 3.0 inches, 3.5 inches, or 4.0 inches.

[0053] The diameter or cross-sectional width of the void 710 may range from 0.25 inches to 0.75 inches. The diameter or cross-sectional width of the void 710 may be 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, or 0.75 inches.

[0054] Referring to Figure 7, the void 710 defines its central axis 1010. The central axis 1010 of the void is aligned with the central axis of the opening. The central axis 1010 of the void is parallel to the axis 370 of the CTP groove. The central axis 1010 of the void may be parallel to the strike surface 140 of the golf club head. Also, the central axis 1010 of the void is directly aligned with the central axis of the opening 210. The central axis 1010 of the void and the central axis of the opening 210 are aligned so that the void 710 can align with the opening 210 and receive the CTP weight 420 into the void 710 without any bending or obstruction.

[0055] Alternatively, the central axis 1010 of the gap can form an angle of -5 to +5 degrees with respect to the strike surface 140 of the golf club head, where a negative angle indicates that the towed portion of the central axis 1010 of the gap is angled toward the strike surface 140 of the golf club head, and a positive angle indicates that the towed portion of the central axis 1010 of the gap is angled away from the strike surface 140 of the golf club head.

[0056] Referring further to Figure 7, the central axis 1010 of the gap defines the angle 1020 of the gap with the ground surface 1000 when the golf club is in the address position. The angle 1020 may be in the range of 0 to 30 degrees.

[0057] Furthermore, referring to Figure 7, the angle 1020 of the central axis of the gap relative to the ground surface 1000 when the golf club is in address position may be 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 degrees.

[0058] Referring further to Figure 7, the angle 1020 of the central axis of the gap is angled toward the top rail 120 and toe end 110 of the golf club head 100. The gap 710 is configured to receive the CTP weight 420. Once the CTP weight 420 is received in the gap 710, the orientation of the CTP weight 420 is determined by the orientation of the gap 710, so that the toe end 810 of the weight is close to the top rail 120 and toe end 110 of the golf club head 100.

[0059] The lightweight component 430 may include a metal alloy having a second density lower than the first density of the body 410 of the iron-type golf club head 100. Alternatively, the lightweight component 430 may include a thermosetting or thermoplastic material. In yet another embodiment, the lightweight component 430 may be formed from a die-cast or squeeze-casting alloy such as aluminum, manganese, magnesium, tin, or zinc alloy.

[0060] CTP weight Figures 1-9 all show a single embodiment of the golf club head 100. All numbered features are features of the golf club head 100.

[0061] The CTP weight 420 can add additional mass for the final swing weight of the assembled club. The CTP weight 420 is placed within the gap 710 of the lightweight component 430. The CTP weight includes a size and shape complementary to the gap 710. The CTP weight 420 may be a tapered cylinder or some other tapered shape.

[0062] CTP weight 420 may include steel alloys, titanium alloys, aluminum alloys, plastic polymers, carbon fibers, composites, thermoplastic composites, or any other suitable material.

[0063] CTP weight 420 may contain a mass of 1.0 g to 50.0 g. CTP weight 420 may have a mass of 1.0, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, or 0.42 grams.

[0064] The CTP weight 420 can be securely mounted within the void 710 by adhesive, epoxy resin, welding, brazing, or any other suitable joining method. Alternatively, the CTP weight may be press-fitted into the void 710 without the use of any permanent mounting method. In the alternative case, the first CTP weight 420 is interchangeable with another CTP weight 420. One or more alternative CTP weights 420 may have different mass properties and material composition than the first CTP weight 420. A stopper or cap 450 is used to aesthetically cover the CTP weight 420 and to provide additional mechanical locking to the CTP weight 420 (Figure 4). Alternatively, the stopper or cap 450 may be the primary means of holding the CTP weight 420 within the void 720. In some embodiments, the stopper or cap 450 may be fixed with adhesive. In other embodiments, the stopper or cap 450 may be secured by any other mounting means such as threads, rivets, or press-fitting.

[0065] In some embodiments, the CTP weight 420 may be composed of at least two materials such that the material of the first CTP weight 420 has a lower density than the material of the second CTP weight 420. The CTP weight 420 may have a central portion 820, a heel portion 830, and a toe portion 810. Either the toe portion 810 or the heel portion 830 of the CTP weight 420 may contain the material of the second CTP weight 420. The high-density material in either the heel or toe portion of the CTP weight 420 shifts the center of gravity of the golf club head toward the heel portion 130 or the toe portion 110 of the golf club head.

[0066] Manufacturing method In each embodiment, the golf club head comprises a body having a back cavity. In each embodiment, a lightweight back cavity component having an internal void is placed inside the back cavity. After the lightweight component is placed inside the back cavity, the CTP weight is placed inside the void of the lightweight component through an opening in the heel portion of the body. Then, a cap or stopper is used to close the heel opening and hold the CTP inside the void of the lightweight component.

[0067] In one embodiment, a lightweight back cavity component may be press-fitted into the back cavity by a forging operation for both filling the back cavity of the golf club head and making it appear as a more traditional muscle-back golf club head. In another embodiment, the lightweight back cavity component may be die-cast into the back cavity. In a third embodiment, the lightweight back cavity component may be injection-molded from polymer in one or more parts and attached to the back cavity with adhesive. Alternatively, the lightweight back cavity component may be injection-molded directly from polymer into the back cavity. In each embodiment, the final golf club head further includes:

[0068] Forging Embodiment In one embodiment, the method for forming the golf club head 100, the forging process, utilizes an upper mold, a lower mold, and a pull rod 350.

[0069] The upper mold includes the negative shape of the lightweight component 430. The lower mold includes the negative shape of the front of the main body 410. The pull rod 350 is sized to pass through the opening 210 in the heel of the main body 410 and fit into the back cavity 220 (Figure 3B). The pull rod 350 forms the size and shape of the gap 710 in the lightweight component 430. The main body 410 may also have a groove for the CTP weight 420 at the bottom of the rear cavity.

[0070] In this embodiment, using 3D forging makes it possible and beneficial to securely fix the lightweight part 430 to the body 410 of the golf club 100 using a gap 710 for positioning the CTP weight 420. In typical forging applications, the final geometric shape of the part would be greatly simplified due to the limitations of the forging process, making it impossible to create the gap 710. If the gap 710 is desired in typical forging applications, post-processing steps such as machining must be used. Using the 3D forging process to create the gap 710 is more cost-effective than these alternative methods that produce the same features. The use of the lightweight part 430 also allows for improvements in inertia and center of gravity to improve the performance of the golf club 100 while maintaining the aesthetically pleasing appearance of a muscle-back iron.

[0071] Referring to Figure 9, in one embodiment, the forging process for the lightweight part 430 includes providing an upper forging die and a lower forging die, the upper die receiving the rear of the main club body and compressing the billet of lightweight material to form the back cavity, the insert for the lightweight back cavity, and the lower die receiving the body with the strike surface facing down, the body 410 being placed in the lower forging die and the back cavity 220 being oriented away from the lower forging die (see Figures 3A and 3B). The lightweight billet 310 is placed in the back cavity of the body 410. A pull rod 350 is inserted through an opening 210 in the heel of the body 410 at the base of the billet 310, and the pull rod 350 is restrained in the CTP groove 370 so that the lightweight part 430 does not fill the CTP groove 370 during the forging process. The upper forging die is placed over the back cavity 220 and the billet 310, flush with the lower forging die on the plane of the contact 300, and the lightweight billet 310 is compressed. During the forging / forming process, heat and pressure are applied to deform the lightweight billet 310 into a part, filling the back cavity 220 and lock groove 240 around the outer peripheral side wall 460. The upper forging die, the lower forging die, and the pull rod 350 are removed, and by removing the pull rod 350, a void 710 is created within the lightweight part 430. The golf club head 100 is assembled by inserting the CTP weight 420 into the void 710 through the opening 210, and then closing the opening 210 with a cap or stopper 450.

[0072] Squeeze Casting Embodiment Referring to Figure 10, a method using squeeze or die casting to create a second embodiment of the golf club head 100 involves providing a mold or die-casting device configured to receive the golf club body 410, receiving the golf club body 410 with the strike surface 140 facing downwards, so that the back cavity 220 of the body 410 is exposed within the cavity of the mold or die-casting device. A pull rod 350 is brought into place within the CTP groove 370 of the sole 150 in the back cavity 220 through the heel opening 210 of the body 410. The mold or die-casting device is placed and molten or lightweight plastic material is injected to fill the back cavity 220, thereby forming a lightweight insert part 430 within the back cavity 220. The mold or die is opened, the golf club head 100 is pulled out, and the pull rod 350 is pulled out through the heel opening 210 of the body 410, leaving a gap 710 in the insert 430 of the lightweight back cavity 220 formed by the die-casting or squeeze-casting operation. The golf club head 100 is assembled by inserting the CTP weight 420 into the gap 710 through the opening 210, and then closing the opening 210 with a cap or stopper 450.

[0073] Injection molding embodiment Referring to Figure 11, a method using injection molding to create a third embodiment of the golf club head 100 includes providing an injection mold configured to receive the golf club body 410, the injection mold being configured to receive the golf club body 410 with the strike surface 140 facing down, and to expose the back cavity 220 of the body 410 within the cavity of the injection mold. A pull rod 350 is positioned through an opening 210 in the heel of the body 410 so as to rest within a 150 CTP groove 370 in the back cavity 220. The injection mold is placed in an injection molding apparatus, a lightweight polymer material is injected to fill the back cavity 220 and mold the lightweight insert component 430 within the back cavity 220, the injection mold is opened, the golf club head 100 is removed, and then the rod 350 is pulled out through the opening 210 in the heel of the body 410. Here, the void 710 is left within the insert 430 of the lightweight back cavity 220 formed by the injection molding operation.

[0074] Because the rules of golf can change from time to time (for example, new rules may be adopted, or old rules may be superseded or modified by golf standards organizations and / or governing bodies such as the United States Golf Association (USGA), the Royal and Ancient Golf Clubs of St Andrews (R&A)), golf equipment relating to the devices, methods, and articles of manufacture described herein may or may not conform to the rules of golf at any given time. Accordingly, golf equipment relating to the devices, methods, and products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf equipment. The devices, methods, and articles described herein are not limited in this respect.

[0075] Replacing one or more claimed parts constitutes a reconfiguration, not a repair. Furthermore, with respect to specific embodiments, benefits, other advantages, and solutions to problems have been described. However, effects, advantages, solutions to problems, and any parts or groups of parts that produce or further enhance any of these effects, advantages, or solutions should never be construed as essential, necessary, or fundamental features or parts of any claim, or any of the claims.

[0076] The above examples may relate to wood-type golf clubs, the apparatus, methods, and articles described herein. Alternatively, the apparatus, methods, and articles described herein may be applicable to other types of sports equipment such as hockey sticks, tennis rackets, fishing poles, and ski poles.

[0077] Furthermore, the embodiments and limitations disclosed herein are not considered to be contributed to the public under the doctrine of contribution if (1) the embodiments and / or limitations are not expressly described in the claims and (2) they are equivalent to, or could be equivalent to, the expressive components and / or limitations in the claims under the doctrine of equivalents.

Claims

1. It is an iron-type golf club head, The main club building, Insert and, The cap and Equipped with weight, The aforementioned main club body is, Front and, The rear and, The tip of the stem, The heel end and The strike side, The front of the strike surface, which is designed to impact the golf ball, A horseshoe configured to accept a golf shaft, Top rail and The sole and The rear of the strike face, The outer peripheral side wall formed by the top rail, the sole, the toe end, and the heel end, Equipped with, The outer peripheral wall extends rearward, substantially perpendicular to the strike surface. The back cavity is defined by the outer peripheral wall and the rear surface of the strike surface. The back cavity opens toward the rear of the main club body, The outer peripheral side wall further includes a locking groove recessed into the outer peripheral side wall in at least a portion of the area around the rear surface of the strike surface. The lock groove is recessed into the outer peripheral side wall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface. The aforementioned insert is Front of the insert and The rear of the insert, Insert lock flange and Equipped with, The insert is configured to be received within the back cavity, The insert lock flange is configured to be received within the lock groove, The front surface of the insert is configured to be directly adjacent to the rear surface of the strike surface and to conform to the rear surface of the strike surface. The rear portion of the insert is further, Upper part and The muscle back section, The transition section between the upper part and the muscle back part, Equipped with, The aforementioned muscle back portion surrounds the gap, The main club body further includes an opening in the heel end, The aforementioned opening is a hole that opens outward toward the outer surface of the heel end and also toward the back cavity. When the insert is received in the back cavity, the opening is aligned with the gap, The weight is configured to be received into the gap through the opening. An iron-type golf club head in which the opening is closed by the cap after the weight has been received in the void.

2. The iron-type golf club head according to claim 1, wherein the main club body further comprises a first material having a first density.

3. The iron-type golf club head according to claim 2, wherein the first material is a first metal alloy.

4. The iron-type golf club head according to claim 3, wherein the insert comprises a second material having a second density.

5. The iron-type golf club head according to claim 4, wherein the first density of the first material is greater than the second density of the second material.

6. The upper part of the insert has a first insert thickness, The muscle back portion of the insert has a second insert thickness, The iron-type golf club head according to claim 1, wherein the second insert thickness is greater than the first insert thickness.

7. The iron-type golf club head according to claim 6, wherein the thickness of the second insert is variable.

8. The iron-type golf club head according to claim 1, wherein the void is completely contained within the muscle-back portion of the insert.

9. The aforementioned weight is, The tip of the stem, The central part and, The heel end and Equipped with, The aforementioned weight comprises only one material, as described in claim 1, for the iron-type golf club head.

10. The aforementioned weight is, The tip of the stem, The central part and, The heel end and Equipped with, The aforementioned weight is, The first weight material and The second weight material, Includes, The iron-type golf club head according to claim 1, wherein the first weight material has a lower density than the second weight material.

11. The iron-type golf club head according to claim 10, wherein the weight portion at the heel end includes the second weight material.

12. The iron-type golf club head according to claim 10, wherein the weight portion at the toe end includes the second weight material.

13. The iron-type golf club head according to claim 1, wherein the weight is permanently fixed in the void by means of an adhesive.

14. The iron-type golf club head according to claim 1, wherein the weight is press-fitted and further detachably fixed within the gap by a screw-type cap.

15. The iron-type golf club head according to claim 1, wherein the lock groove has a depth that recedes in the range of 0.1 to 0.5 inches.

16. The lock groove comprises a lock groove bottom and two lock groove side walls, The iron-type golf club head according to claim 1, wherein the locking groove opens into the back cavity of the main body before the back cavity accepts the insert.

17. The iron-type golf club head according to claim 16, wherein the side wall of the lock groove further has a recess perpendicular to the side wall of the lock groove.

18. A method for forming an iron-type golf club head, It includes a step for installing the main club body, a lightweight insert, a cap, and a weight. The aforementioned main club body is, Front and, The rear and, The tip of the stem, The heel end and The strike side, The front of the strike surface, which is designed to impact the golf ball, A horseshoe configured to accept a golf shaft, Top rail and The sole and The rear of the strike face, The outer peripheral side wall formed by the top rail, the sole, the toe end, and the heel end, Equipped with, The outer peripheral wall extends rearward, substantially perpendicular to the strike surface. The back cavity is defined by the outer peripheral wall and the rear surface of the strike surface. The back cavity opens toward the rear of the main club body, The outer peripheral side wall further includes a locking groove recessed into the outer peripheral side wall in at least a portion of the area around the rear surface of the strike surface. The lock groove is recessed into the outer peripheral side wall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface. The main club body is provided with an opening in the heel end, The aforementioned opening is a hole that opens outward toward the outer surface of the heel end and also toward the back cavity. The main club body further comprises a first material having a first density, The first material is a first metal alloy, The above method further, The steps include providing a forging die that includes an upper die platen and a lower die platen, The steps include: positioning the main body within the lower die platen of the forging die with the front surface of the strike surface facing downwards and the back cavity facing upwards; A step of placing a bullet having a second material into the back cavity, wherein the second material has a second density less than the first density, Under the aforementioned bullet, the step of inserting the pull rod into the back cavity through the opening, The steps include pressing the upper mold platen on the lower mold platen to form the lightweight insert, The steps include raising the upper mold platen, pulling out the pull rod through the opening, and forming a void within the lightweight insert, The steps include receiving a weight into the opening through the opening, The steps include closing the opening with the cap, A method that includes [a certain feature].

19. A method for forming an iron-type golf club head, It includes a step for installing the main club body, insert, cap, and weight, The aforementioned main club body is, Front and, The rear and, The tip of the stem, The heel end and The strike side, The front of the strike surface, which is designed to impact the golf ball, A horseshoe configured to accept a golf shaft, Top rail and The sole and The rear of the strike face, The outer peripheral side wall formed by the top rail, the sole, the toe end, and the heel end, Equipped with, The outer peripheral wall extends rearward, substantially perpendicular to the strike surface. The back cavity is defined by the outer peripheral wall and the rear surface of the strike surface. The back cavity opens toward the rear of the main club body, The outer peripheral side wall further includes a locking groove recessed into the outer peripheral side wall in at least a portion of the area around the rear surface of the strike surface. The lock groove is recessed into the outer peripheral side wall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface. The main club body is provided with an opening in the heel end, The aforementioned opening is a hole that opens outward toward the outer surface of the heel end and also toward the back cavity. The main club body further comprises a first material having a first density, The first material is a first metal alloy, The above method further, Steps include creating a mold for the squeeze cast, The steps include: positioning the main club body inside the squeeze cast mold such that the back cavity is exposed inside the squeeze cast mold; The steps include inserting the pull rod into the back cavity, A step of heating a second metal alloy to a plasticizing temperature, forcing the second material into the squeeze cast mold, and forming the lightweight insert in the back cavity of the main club body, wherein the second material has a second density lower than the first density, The steps include opening the mold of the squeeze cast, pulling out the pull rod through the opening, and forming a void within the lightweight insert, The steps include receiving a weight into the opening through the opening, The steps include closing the opening with the cap, A method that includes [a certain feature].

20. A method for forming an iron-type golf club head, It includes a step for installing the main club body, insert, cap, and weight, The aforementioned main club body is, Front and, The rear and, The tip of the stem, The heel end and The strike side, The front of the strike surface, which is designed to impact the golf ball, A horseshoe configured to accept a golf shaft, Top rail and The sole and The rear of the strike face, The outer peripheral side wall formed by the top rail, the sole, the toe end, and the heel end, Equipped with, The outer peripheral wall extends rearward, substantially perpendicular to the strike surface. The back cavity is defined by the outer peripheral wall and the rear surface of the strike surface. The back cavity opens toward the rear of the main club body, The outer peripheral side wall further includes a locking groove recessed into the outer peripheral side wall in at least a portion of the area around the rear surface of the strike surface. The lock groove is recessed into the outer peripheral side wall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface. The main club body is provided with an opening in the heel end, The aforementioned opening is a hole that opens outward toward the outer surface of the heel end and also toward the back cavity. The main club body further comprises a first material having a first density, The first material is a first metal alloy, The above method further, The steps include: providing a mold for plastic injection molding, The steps include positioning the main club body within a plastic injection molding mold such that the back cavity is exposed inside the squeeze cast mold, The steps include inserting the pull rod into the back cavity, A step of heating a thermoplastic plastic material and forcing the thermoplastic plastic material into a plastic injection molding mold to form the lightweight insert in the back cavity of the main club body, wherein the second material has a second density lower than the first density, The steps include opening the plastic injection mold, pulling out the pull rod through the opening, and forming a void within the lightweight insert, The steps include receiving a weight into the opening through the opening, The steps include closing the opening with the cap, A method that includes [a certain feature].

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