Forged Iron Heads

Abstract

To address the need in a technical field for an iron-type golf club head having an improved mass distribution for improved inertia while also retaining aesthetics of a full muscle-back iron.SOLUTION: There is provided an iron-type golf club head having an optimized mass distribution while also having aesthetics of a full muscle-back iron. The iron-type golf club head 100 comprises a main club head body 410, a lightweight, back-cavity insert, and a void within the lightweight, the back-cavity insert configured to receive a CTP weight capable of adjusting mass characteristics of the iron-type golf club head.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 839,411, filed April 26, 2019.

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

[0003] There is a need in the art for an iron-type golf club head that has improved mass distribution for improved inertia, but also maintains the aesthetics of a full muscle-back iron.

[0004] The invention described herein is an iron-type golf club head having optimized mass distribution while also having the aesthetics of a full muscle back iron. The iron-type golf club head includes a main club head body, a lightweight back cavity insert, and a void within the lightweight back cavity insert configured to receive a CTP weight that can adjust the mass properties of the iron-type golf club head. [Brief explanation of the drawings]

[0005] FIELD OF THE DISCLOSURE The present disclosure relates generally to sports equipment, and more particularly to golf club heads and related methods.

[0006] [Figure 1] 1 shows a front view of an iron-type golf club head at address relative to the ground surface.

[0007] [Figure 2] 1 shows a cross section of an iron-type golf club head with a back cavity and an opening through the heel end.

[0008] [Figure 3A]1 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] 1 shows an iron-type golf club head having 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] 1 shows an exploded view of an iron-type golf club head.

[0011] [Figure 4B] 1 shows an exploded view of an iron-type golf club head.

[0012] [Figure 4C] 1 shows an exploded view of an iron-type golf club head.

[0013] [Figure 5A] 1 shows the main club body and lightweight back cavity insert of an iron-type golf club head.

[0014] [Figure 5B] FIG. 10 is a bottom cross-sectional view showing the voids within the lightweight back cavity insert.

[0015] [Figure 6] Lightweight back cavity insert shown.

[0016] [Figure 7A] 1 shows an iron-type golf club head having a void within a lightweight back cavity insert.

[0017] [Figure 7B] 1 shows an iron-type golf club head with weights within the voids.

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

[0019] [Figure 9] 1 illustrates a method of forming a golf club head.

[0020] [Figure 10] 1 illustrates a method of forming a golf club head.

[0021] [Figure 11] 1 illustrates a method of forming a golf club head.

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

[0023] Other aspects of the present disclosure will become apparent by consideration of the detailed description and accompanying drawings. DETAILED DESCRIPTION OF THE INVENTION

[0024] The iron-type golf clubs described herein offer both the visual aesthetics of a traditional muscle-back iron-type golf club head, and the mass properties of a more forgiving cavity-back iron-type golf club head and the ability to adjust the club head's center of gravity provided by removable CTP weights. The iron-type golf club head includes a back cavity that allows for more mass to be moved to the periphery of the golf club head. A lightweight back cavity component or components are attached within the back cavity. The golf club head further includes a CTP weight received with a void within the lightweight component that allows for the change in mass properties by configuring the mass of the CTP weight.

[0025] In the specification and claims, the terms "first," "second," "third," "fourth," etc., if any, are used to distinguish between similar parts and are not necessarily used to describe a particular sequence or chronological order, and it should be understood that terms so used are interchangeable under appropriate circumstances; for example, the embodiments described herein may operate in sequences other than those depicted or otherwise described herein. Furthermore, the terms "comprise," "have," and any variations thereof, do not necessarily mean that a process, method, system, article, device, or apparatus that includes a list of parts is limited to those parts, but may include other parts not expressly listed or inherent in such process, method, system, article, apparatus, or apparatus.

[0026] The terms "left," "right," "front," "rear," "top," "bottom," "upper," "lower," etc. in the specification and claims, if any, are used for descriptive purposes and are not necessarily used to describe permanent relative positions. It is to be understood that terms so used are interchangeable under appropriate circumstances, such that embodiments of the apparatus, methods, and / or articles of manufacture described herein can, for example, operate in other orientations other than those illustrated or otherwise described herein.

[0027] Before any embodiment of the present disclosure is described in detail, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of parts set forth in the following description or illustrated in the following drawings. The present disclosure is capable of other embodiments and of being practiced or carried out in various ways.

[0028] Aspects of golf clubs described herein may be applied to one or more golf clubs in an iron set. In embodiments, a set of irons includes irons with variable club head sizes, shaft lengths, lie angles, loft angles, head weights, 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, wedges, and utility clubs. Additionally, an iron set may include one or more wedges with higher loft angles than the numbered irons.

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

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

[0031] In many embodiments, the golf club head can include a total volume between 1.9 cubic inches and 2.7 cubic inches. In some embodiments, the total volume of the golf club head can be between 1.9 cubic inches and 2.4 cubic inches, 2.0 cubic inches and 2.5 cubic inches, 2.1 cubic inches and 2.6 cubic inches, 2.2 cubic inches and 2.7 cubic inches, 2.3 cubic inches and 2.7 cubic inches, or 2.4 cubic inches and 2.7 cubic inches. In other embodiments, the total volume of the golf club head can 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 can have a total mass between 200 grams and 300 grams. In some embodiments, the golf club head can have a total mass between 200 grams and 210 grams, 210 grams and 220 grams, 220 grams and 230 grams, 230 grams and 240 grams, 240 grams and 250 grams, 250 grams and 260 grams, 255 grams and 260 grams, 260 grams and 270 grams, 265 grams and 275 grams, 270 grams and 280 grams, 275 grams, and 280 grams, or 250 grams and 270 grams. In other embodiments, the total mass may 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] The main body of the golf club head The iron-type golf club head includes a body having a back cavity that allows for more mass to be moved to the periphery of the golf club head. A lightweight back cavity component or insert is mounted within the back cavity. The golf club head further includes a CTP weight received within the lightweight component with a void, and the mass of the CTP weight allows for a change in mass properties by moving the center of gravity of the golf club head toward the toe or heel.

[0034] 1 and 2 , a body 410 of an iron-type golf club head 100 has a toe end 110, a heel end, a front portion having a striking surface 140 for impacting a golf ball, a hosel, a top rail 120, a sole, a hosel configured to receive a shaft, a rear portion opposite the front portion, a back cavity 220 surrounded and defined by a rear surface 230 of the striking surface 140, and an outer peripheral sidewall 460. The outer peripheral sidewall 460 surrounds 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 toward the rear of the body 410 than the top rail 120. Therefore, the lower portion of the outer peripheral sidewall 460 extends further toward the rear than the upper portion of the outer peripheral sidewall 460. The back cavity 220 has a depth, and the depth of the back cavity 220 is greater at the lower, soleward portion than at the upper, top rail 120 portion of the back cavity 220 .

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

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

[0037] 2 and 4A, the perimeter sidewall 460 is generally perpendicular to the rear surface 230. The perimeter sidewall 460 may vary from perpendicular by plus or minus 5 degrees. The heel end 130 of the golf club head 100 may have an opening 210 therethrough such that the opening 210 opens to the outer surface of the heel end 130 and into the back cavity 220.

[0038] 2 and 4A, the outer peripheral sidewall 460 includes a locking groove 240 therein that follows the perimeter of the back cavity 220. The locking groove 240 is recessed into the outer peripheral sidewall 460 that surrounds the rear surface 230. The locking groove 240 is recessed into the outer peripheral sidewall 460 in a direction parallel to the rear surface 230 of the strike face 140 (see FIG. 2).

[0039] 2, the locking groove 240 includes a locking groove bottom and two locking groove sidewalls. The locking groove opens into the back cavity 220 of the body 410 before the back cavity 220 receives the lightweight insert 430. The locking groove 240 can define a plane, where the plane intersects the center of the locking groove 240 bottom around the peripheral sidewall 460 and the plane is essentially parallel to the strike face 140.

[0040] 2, the locking groove 240 may have a single, constant depth. In other embodiments, the depth of the locking groove 240 may vary. The locking groove 240 may have a single, constant width. In other embodiments, the width of the locking groove 240 may vary. The locking groove 240 may be continuous around the entire peripheral sidewall 460. The locking groove 240 may be discontinuous or may form multiple sections separated from one another around the peripheral sidewall 460. The locking groove 240 may include a protrusion or depression along the bottom of the lock 240. The sidewall of the locking groove 240 may include a depression or depression in the sidewall of the locking groove 240, and the depression or depression may be perpendicular to the sidewall 240 of the locking groove (not shown).

[0041] Still referring to FIG. 2, the depth of the locking groove 240 may range from 0.1 inches to 0.5 inches. The depth of the locking groove 240 may be 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, or 0.5 inches. The width of the locking groove 240 may range from 0.1 inches to 0.5 inches. The width of the locking groove 240 may be 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, or 0.5 inches.

[0042] 4A and 4B , the sole 150 further includes a CTP weight groove 370. The CTP weight groove 370 includes a CTP weight groove 370 axis along the length of the CTP weight groove 370. As a result, the axis of the CTP weight groove 370 is equidistant from the edge of the CTP weight groove 370 along the length of the CTP weight groove 370 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 face 140. The axis of the central CTP weight groove 370 defines an angle with the ground plane 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 in the void 710.

[0043] 4A and 4B, when the golf club head 100 is in the address position, the axis angle of the CTP weight groove 370 relative to the ground plane 1000 may be between 0 and 30 degrees. The axis 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] 4A and 4B , the CTP weight groove 370 has a length, a width, and a recess depth. The depth of the CTP weight groove 370 is measured relative to the surface of the surrounding outer circumferential sidewall 460 of the sole 150 such that the CTP weight groove 370 defines a recess in the outer circumferential sidewall 460 of the sole 150. The recess depth of the CTP weight groove 370 gradually decreases as it extends from a location 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 CTP weight groove 370 gradually decreases from a location closest to the heel end 130 of the golf club head as it extends toward the toe end 110 of the golf club head. The groove 370 of the CTP weight 420 tapers to a terminus at 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 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 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 which the CTP weight groove 370 begins to recess from the perimeter sidewall 460 of the sole 150.

[0045] 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 a depth and a cross-sectional area. The opening 210 defines a central axis that 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 having a radius of curvature. In other embodiments, the opening 210 includes any geometric cross-sectional shape (see FIG. 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 perimeter sidewall 460.

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

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

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

[0049] 2A, 2B, and 2C, a lightweight component 430 resides within the back cavity 220 of the body 410 to provide a clean muscle-back aesthetic. The lightweight component 430 includes an upper portion 620, a lower muscle-back portion 640, and a transition portion 630 between the upper portion 620 and the lower muscle-back portion 640. The upper portion 620 does not extend further rearward than the top rail 120 of the body 410. The lower muscle-back portion 640 does not extend further rearward than the sole 150 of the body 410. The upper portion 620 defines a first insert thickness. The lower muscle-back portion 640 defines a second insert thickness. The thickness of the second insert may vary. The second insert thickness may have a maximum thickness between the sole portion of the perimeter sidewall 460 and the insert transition portion 630. The second insert thickness is greater than the first insert thickness. The insert transition 630 includes a thickness that transitions from the thickness of the first insert to the thickness of the second insert.

[0050] 2, 4A, 4B, 4C, 5A, and 6, the lightweight component 430 includes a locking flange 610 configured to be received within a locking groove 240 in the outer peripheral sidewall 460 of the back cavity 220, providing a mechanical lock to retain the lightweight component 430 within the back cavity 220. The lightweight component 430 surrounds a void 710 for retaining the CTP weight 420, such that the void 710 aligns with the opening 210 in the heel of the main body 410. The opening 210 in the main body 410 and the void 710 in the lightweight component 430 combine to receive the CTP weight 420 (FIG. 4C). The void 710 may be located within the lower muscle-back portion 640 of the lightweight component 430. No portion of the void 710 is located within the transition portion 630 or upper portion 620 of the lightweight component 430.

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

[0052] The length of the gap 710 can range from 2.0 inches to 4.0 inches. The length of the gap 710 can also 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 can range from 0.25 inches to 0.75 inches. The diameter or cross-sectional width of the void 710 can also 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] 7 , the void 710 defines a void central axis 1010. The void central axis 1010 is aligned with the central axis of the opening. The void central axis 1010 is parallel to the CTP groove axis 370. The void central axis 1010 may be parallel to the strike face 140 of the golf club head. Additionally, the void central axis 1010 is directly aligned with the central axis of the opening 210. The void central axis 1010 and the central axis of the opening 210 are aligned so that the void 710 is aligned with the opening 210 to receive the CTP weight 420 without any bending or obstruction into the void 710.

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

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

[0057] Still referring to FIG. 7 , the angle 1020 of the central axis of the air gap relative to the ground plane 1000 when the golf club is at address 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] 7 , the angle 1020 of the void's central axis is angled toward the top rail 120 and toe end 110 of the golf club head 100. The void 710 is configured to receive the CTP weight 420. When the CTP weight 420 is received within the void 710, the orientation of the CTP weight 420 is determined by the orientation of the void 710, so that the CTP weight 420 is also angled toward the top rail 120 and toe end 110 of the golf club head 100 such that the toe end 810 of the weight is proximate the top rail 120 and toe end 110 of the golf club head 100.

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

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

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

[0062] The CTP weight 420 may comprise a steel alloy, a titanium alloy, an aluminum alloy, a plastic polymer, a carbon fiber composite, a thermoplastic composite, or any other suitable material.

[0063] CTP weight 420 may include a mass between 1.0 g and 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 may be securely attached within the cavity 710 by adhesive, epoxy, welding, brazing, or any other suitable joining method. Alternatively, the CTP weight may be press-fit into the cavity 710 without any permanent attachment method. Alternatively, the first CTP weight 420 may be interchangeable with another CTP weight 420. One or more replacement CTP weights 420 may have different mass properties and material composition than the first CTP weight 420. A stopper or cap 450 may be utilized to aesthetically cover the CTP weight 420 and provide an additional mechanical lock for the CTP weight 420 ( FIG. 4 ). Alternatively, the stopper or cap 450 may be the primary means of retaining the CTP weight 420 within the cavity 720. In some embodiments, the stopper or cap 450 may be secured with an adhesive. In other embodiments, the stopper or cap 450 may be secured by any other attachment means, such as threads, rivets, a press fit, or the like.

[0065] In some embodiments, the CTP weight 420 may be constructed from 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 end portion 830, and a toe end portion 810. Either the toe end portion 810 or the heel end portion 830 of the CTP weight 420 may comprise the material of the second CTP weight 420. The higher density material in either the heel end or toe end of the CTP weight 420 shifts the center of gravity of the golf club head toward the heel end 130 or toe end 110 of the golf club head.

[0066] Manufacturing method In each embodiment, the golf club head includes a body having a back cavity. In each embodiment, a lightweight back cavity component further comprising an internal void is disposed within the back cavity. After the lightweight component is disposed within the back cavity, a CTP weight is disposed within the internal void of the lightweight component through an opening in a heel portion of the body. A cap or stopper is then used to close the heel opening and retain the CTP within the void of the lightweight component.

[0067] In one embodiment, a lightweight back cavity component may be press-fit into the back cavity via a forging operation to both fill the back cavity of the golf club head and create the appearance of 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 a polymer in one or more pieces and attached to the back cavity with an adhesive. Alternatively, the lightweight back cavity component may be injection molded directly from a 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, a forging process, utilizes an upper die, a lower die, and a pull rod 350.

[0069] The top mold contains the negative shape of the lightweight part 430. The bottom mold has a negative shape of the front of the body 410. The pull rod 350 is sized to fit through the opening 210 in the heel of the body 410 and into the back cavity 220 (FIG. 3B). The pull rod 350 forms the size and shape of the void 710 in the lightweight part 430. The body 410 may also have a groove for the CTP weight 420 in the bottom of the back cavity.

[0070] In this embodiment, 3D forging can be used to advantageously secure the lightweight component 430 to the body 410 of the golf club 100, with the void 710 for placement of the CTP weight 420. In a typical forging application, the final geometry of the component would be so simplified due to the limitations of the forging process that it would not be possible to create the void 710. If the void 710 were desired in a typical forging application, a post-processing step, such as machining, must be used. Using a 3D forging process to create the void 710 is more cost-effective than these alternative methods of creating the same feature. The use of the lightweight component 430 can also allow 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] 9, in one embodiment, the forging process for lightweight part 430 includes providing an upper forging die and a lower forging die, where the upper die receives the rear portion of the main club body and compresses a billet of lightweight material to form the back cavity, the lightweight back cavity insert, and the lower die is configured to receive the body with its strike face down and place the body 410 in the lower forging die with the back cavity 220 facing away from the lower forging die (see FIGS. 3A and 3B). A lightweight billet 310 is placed within the back cavity of the body 410. A pull rod 350 is inserted through an opening 210 in the heel of the body 410 beneath the billet 310, and the pull rod 350 rests within the CTP groove 370 so that the lightweight part 430 does not fill the CTP groove 370 during the forging process. An upper forging die is placed over the back cavity 220 and billet 310, with the flat of the contact 300 flush with the lower forging die, and the lightweight billet 310 is compressed. Heat and pressure are applied during the forging / forming process to deform the lightweight billet 310 into a part, filling the back cavity 220 and locking groove 240 around the outer perimeter sidewall 460. The upper forging die, lower forging die, and pull rod 350 are removed, and removal of the pull rod 350 creates a void 710 in the lightweight part 430. The golf club head 100 is assembled by inserting a CTP weight 420 into the void 710 through the opening 210, which is then closed with a cap or stopper 450.

[0072] Squeeze cast embodiment 10 , a method of using squeeze or die casting to create the second embodiment of the golf club head 100 includes providing a die or mold configured to receive the golf club body 410 with the strike face 140 facing down, with the back cavity 220 of the body 410 exposed within the cavity of the die or mold. A pull rod 350 is passed through the heel opening 210 of the body 410 and rests within the CTP groove 370 of the sole 150 within the back cavity 220. The die or mold is placed in a die casting or squeeze casting apparatus, and a lightweight material, such as molten or plastic, is injected to fill the back cavity 220 and form the lightweight insert part 430 within the back cavity 220. The die or mold is opened, the golf club head 100 is pulled out, and the pull rod 350 is pulled out through the opening 210 in the heel of the body 410, leaving a void 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 void 710 through the opening 210 and then closing the opening 210 with a cap or stopper 450.

[0073] Injection Molding Embodiment 11 , a method of using injection molding to create the third embodiment of the golf club head 100 includes providing an injection mold configured to receive the golf club body 410 with the strike face 140 facing down and the back cavity 220 of the body 410 exposed within the cavity of the injection mold. A pull rod 350 is placed through the heel opening 210 of the body 410 so that it rests within the 150 CTP groove 370 in the back cavity 220. The injection mold is placed within an injection molding machine, a lightweight polymer material is injected to fill the back cavity 220 and mold the lightweight insert 430 into the back cavity 220, the injection mold is opened, the golf club head 100 is removed, and the rod 350 is then pulled through the heel opening 210 of the body 410. Here, a 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 may change from time to time (e.g., new Rules may be adopted, or old Rules may be eliminated or modified by golf standards organizations and / or governing bodies, such as the United States Golf Association (USGA) or the Royal and Ancient Golf Club of St. Andrews (R&A)), golf equipment related to the apparatus, methods, and articles of manufacture described herein may or may not conform to the Rules of golf at any particular time. Accordingly, golf equipment related to the apparatus, methods, and products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf equipment. The apparatus, methods, and articles of manufacture described herein are not limited in this respect.

[0075] Substitution of one or more claimed parts constitutes a reconfiguration, not a repair. Furthermore, benefits, other advantages, and solutions to problems have been described with respect to particular embodiments. However, the benefit, advantage, solution, and any component or components that provide or further enhance the benefit, advantage, or solution should in no way be construed as an essential, required, or essential feature or component of any or all of these claims.

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

[0077] Furthermore, the embodiments and limitations disclosed in this specification are not offered to the public under the doctrine of contribution if the embodiment and / or limitation (1) is not expressly recited in the claims and (2) is or could be equivalent to the expressive elements and / or limitations in the claims under the doctrine of equivalents. The features of the technology disclosed in this specification are listed below. (Item 1) An iron-type golf club head, The main club itself, The insert and Cap and It is equipped with a weight and The main club body is The front and The rear and A toe end portion, A heel end portion; Strike surface and a front surface of the striking face configured to impact a golf ball; a hosel configured to receive a golf shaft; The top rail and Sole and the rear of the strike surface; an outer peripheral sidewall formed by the top rail, the sole, the toe end, and the heel end; Equipped with The outer peripheral sidewall extends rearward substantially perpendicular to the strike surface, a back cavity is defined by the outer peripheral sidewall and the rear surface of the strike face; the back cavity is open toward the rear of the main club body; the outer peripheral sidewall further includes a locking groove recessed into the outer peripheral sidewall around at least a portion of the rear surface of the strike face; the lock groove is recessed into the outer peripheral sidewall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface; The insert is The front of the insert and The rear of the insert; An insert lock flange; Equipped with the insert is configured to be received within the back cavity; the insert locking flange is configured to be received within the locking groove; the insert forward surface is configured to be directly adjacent to and conform to the strike face aft surface; The insert rear portion further comprises: An upper part and Muscle back section and a transition portion between the upper portion and the muscle back portion; Equipped with the muscle back portion surrounds a void; the main club body further comprising an opening in the heel end; the opening is a hole that opens onto the outer surface of the heel end and into the back cavity; the opening aligns with the gap when the insert is received in the back cavity; the weight is configured to be received within the gap through the opening; an iron-type golf club head, wherein the opening is closed by the cap after the weight is received in the gap; (Item 2) 2. The iron-type golf club head according to item 1, wherein the main club body further comprises a first material having a first density. (Item 3) 3. The iron-type golf club head according to item 2, wherein the first material is a first metal alloy. (Item 4) 4. The iron-type golf club head according to item 3, wherein the insert includes a second material having a second density. (Item 5) 5. The iron-type golf club head according to item 4, wherein the first density of the first material is greater than the second density of the second material. (Item 6) a top portion of the insert having a first insert thickness; the muscle back portion of the insert has a second insert thickness; 2. The iron-type golf club head according to item 1, wherein the second insert thickness is greater than the first insert thickness. (Item 7) 7. The iron-type golf club head according to item 6, wherein the second insert thickness is variable. (Item 8) Item 2. The iron-type golf club head according to item 1, wherein the void is completely contained within the muscle back portion of the insert. (Item 9) The weight is A toe end portion, The central part and A heel end portion, Equipped with Item 2. The iron-type golf club head according to item 1, wherein the weight comprises only one material. (Item 10) The weight is A toe end portion, The central part and A heel end portion, Equipped with The weight is a first weight material; a second weight material; and Including, 2. The iron-type golf club head according to item 1, wherein the first weight material has a density lower than that of the second weight material. (Item 11) Item 11. The iron-type golf club head according to item 10, wherein the heel end weight portion includes the second weight material. (Item 12) Item 11. The iron-type golf club head according to item 10, wherein the toe end weight portion includes the second weight material. (Item 13) Item 2. The iron-type golf club head of item 1, wherein the weight is permanently secured within the cavity by means of an adhesive. (Item 14) Item 2. The iron-type golf club head according to item 1, wherein the weight is press-fitted or further removably fixed in the cavity by a screw-type cap. (Item 15) Item 2. The iron-type golf club head according to item 1, wherein the locking groove has a recessed depth in the range of 0.1 to 0.5 inches. (Item 16) The locking groove includes a locking groove bottom and two locking groove side walls; 2. The iron-type golf club head according to item 1, wherein the locking groove opens into the back cavity of the main body before the back cavity receives the insert. (Item 17) Item 17. The iron-type golf club head according to item 16, wherein the locking groove sidewall further has a recession perpendicular to the locking groove sidewall. (Item 18) 1. A method for forming an iron-type golf club head, comprising: providing a main club body, a lightweight insert, a cap, and a weight; The main club body is The front and The rear and A toe end portion, A heel end portion; Strike surface and a front surface of the striking face configured to impact a golf ball; a hosel configured to receive a golf shaft; The top rail and Sole and the rear of the strike surface; an outer peripheral sidewall formed by the top rail, the sole, the toe end, and the heel end; Equipped with The outer peripheral sidewall extends rearward substantially perpendicular to the strike surface, a back cavity is defined by the outer peripheral sidewall and the rear surface of the strike face; the back cavity is open toward the rear of the main club body; the outer peripheral sidewall further includes a locking groove recessed into the outer peripheral sidewall around at least a portion of the rear surface of the strike face; the lock groove is recessed into the outer peripheral sidewall, 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 including an opening in the heel end; the opening is a hole that opens onto the outer surface of the heel end and into the back cavity; the main club body further comprising a first material having a first density; the first material is a first metal alloy; The method further comprises: providing a forging die including an upper die platen and a lower die platen; placing the body in the lower die platen of the forging die with the front of the strike face facing downward and the back cavity facing upward; placing a bullet having a second material into the back cavity, the second material having a second density less than the first density; inserting a pull rod through the opening into the back cavity under the bullet; pressing the upper mold platen over the lower mold platen to form the lightweight insert; raising the upper mold platen to withdraw the pull rod through the opening to form a void in the lightweight insert; receiving a weight through the opening and into the opening; closing the opening with the cap; A method comprising: (Item 19) 1. A method for forming an iron-type golf club head, comprising: providing a main club body, an insert, a cap, and a weight; The main club body is The front and The rear and A toe end portion, A heel end portion; Strike surface and a front surface of the striking face configured to impact a golf ball; a hosel configured to receive a golf shaft; The top rail and Sole and the rear of the strike surface; an outer peripheral sidewall formed by the top rail, the sole, the toe end, and the heel end; Equipped with The outer peripheral sidewall extends rearward substantially perpendicular to the strike surface, a back cavity is defined by the outer peripheral sidewall and the rear surface of the strike face; the back cavity is open toward the rear of the main club body; the outer peripheral sidewall further includes a locking groove recessed into the outer peripheral sidewall around at least a portion of the rear surface of the strike face; the lock groove is recessed into the outer peripheral sidewall, 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 including an opening in the heel end; the opening is a hole that opens onto the outer surface of the heel end and into the back cavity; the main club body further comprising a first material having a first density; the first material is a first metal alloy; The method further comprises: providing a squeeze cast mold; placing the main club body within the squeeze cast mold such that the back cavity is exposed within the squeeze cast mold; Inserting a pull rod into the back cavity; heating a second metal alloy to a plastic temperature to force the second material into the squeeze cast mold to form the lightweight insert in the back cavity of the main club body, the second material having a second density lower than the first density; opening the squeeze cast mold and withdrawing the pull rod through the opening to form a void within the lightweight insert; receiving a weight through the opening and into the opening; closing the opening with the cap; A method comprising: (Item 20) 1. A method for forming an iron-type golf club head, comprising: providing a main club body, an insert, a cap, and a weight; The main club body is The front and The rear and A toe end portion, A heel end portion; Strike surface and a front surface of the striking face configured to impact a golf ball; a hosel configured to receive a golf shaft; The top rail and Sole and the rear of the strike surface; an outer peripheral sidewall formed by the top rail, the sole, the toe end, and the heel end; Equipped with The outer peripheral sidewall extends rearward substantially perpendicular to the strike surface, a back cavity is defined by the outer peripheral sidewall and the rear surface of the strike face; the back cavity is open toward the rear of the main club body; the outer peripheral sidewall further includes a locking groove recessed into the outer peripheral sidewall around at least a portion of the rear surface of the strike face; the lock groove is recessed into the outer peripheral sidewall, 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 including an opening in the heel end; the opening is a hole that opens onto the outer surface of the heel end and into the back cavity; the main club body further comprising a first material having a first density; the first material is a first metal alloy; The method further comprises: providing a plastic injection mold; placing the main club body within a plastic injection mold such that the back cavity is exposed within the squeeze cast mold; Inserting a pull rod into the back cavity; heating a thermoplastic plastic material to force the thermoplastic plastic material into the plastic injection mold to form the lightweight insert in the back cavity of the main club body, the second material having a second density less than the first density; opening the plastic injection mold and pulling the pull rod through the opening to form a void in the lightweight insert; receiving a weight through the opening and into the opening; closing the opening with the cap; A method comprising:

Claims

1. An iron-type golf club head, The main club itself, The insert and Cap and It is equipped with a weight and The main club body is The front and The rear and A toe end portion, A heel end portion; Strike surface and a front surface of the striking face configured to impact a golf ball; a hosel configured to receive a golf shaft; The top rail and Sole and the rear of the strike surface; an outer peripheral sidewall formed by the top rail, the sole, the toe end, and the heel end; Equipped with The outer peripheral sidewall extends rearward substantially perpendicular to the strike surface, a back cavity is defined by the outer peripheral sidewall and the rear surface of the strike face; the back cavity is open toward the rear of the main club body; the outer peripheral sidewall further includes a locking groove recessed into the outer peripheral sidewall around at least a portion of the rear surface of the strike face; the lock groove is recessed into the outer peripheral sidewall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface; The insert is The front of the insert and The rear of the insert; An insert lock flange; Equipped with the insert is configured to be received within the back cavity; the insert locking flange is configured to be received within the locking groove; the insert forward surface is configured to be directly adjacent to and conform to the strike face aft surface; The insert rear portion further comprises: An upper part and Muscle back section and a transition portion between the upper portion and the muscle back portion; Equipped with the muscle back portion surrounds a void; the void defines a void central axis; an air gap angle is defined between a central axis of the air gap and a ground plane when the iron-type golf head is in an address position; the gap angle is between 0 and 30 degrees; the main club body further comprising an opening in the heel end; the opening is a hole that opens onto the outer surface of the heel end and into the back cavity; the opening aligns with the gap when the insert is received in the back cavity; the weight is configured to be received within the gap through the opening; the weight comprises only one material; an iron-type golf club head, wherein the opening is closed by the cap after the weight is received in the cavity;

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

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

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

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

6. a top portion of the insert having a first insert thickness; the muscle back portion of the insert has a second insert thickness; The iron-type golf club head of claim 1 , wherein the second insert thickness is greater than the first insert thickness.

7. 7. The iron-type golf club head according to claim 6, wherein the thickness of the second insert at a portion farther from the transition portion is greater than the thickness of the second insert at a portion closer to the transition portion.

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

9. 2. The iron-type golf club head of claim 1, wherein said weight is permanently secured within said cavity by means of an adhesive.

10. An iron-type golf club head as described in claim 1, wherein the weight is press-fitted and further removably fixed within the gap by a screw-type cap.

11. An iron-type golf club head as described in claim 1, wherein the locking groove has a recessed depth in the range of 2.54 millimeters to 12.7 millimeters.

12. The locking groove comprises a locking groove bottom and two locking groove side walls; 2. 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 receives the insert.

13. An iron-type golf club head as described in claim 12, wherein the lock groove side wall further has a recession perpendicular to the lock groove side wall.

14. The iron-type golf club head according to claim 1 , wherein a central axis of the void is parallel to the strike surface.

15. a central axis of the void forms an angle of between −5 degrees and +5 degrees with respect to the strike face; a negative angle indicates that a forward portion of the central axis of the void is angled toward the strike face; 2. The iron-type golf club head of claim 1, wherein a positive angle indicates that a forward portion of the central axis of the void is angled away from the strike face.

16. An iron-type golf club head, The main club itself, The insert and Cap and It is equipped with a weight and The main club body is The front and The rear and A toe end portion, A heel end portion; Strike surface and a front surface of the striking face configured to impact a golf ball; a hosel configured to receive a golf shaft; The top rail and Sole and the rear of the strike surface; an outer peripheral sidewall formed by the top rail, the sole, the toe end, and the heel end; Equipped with The outer peripheral sidewall extends rearward substantially perpendicular to the strike surface, a back cavity is defined by the outer peripheral sidewall and the rear surface of the strike face; the back cavity is open toward the rear of the main club body; the outer peripheral sidewall further includes a locking groove recessed into the outer peripheral sidewall around at least a portion of the rear surface of the strike face; the lock groove is recessed into the outer peripheral sidewall, offset rearward from the rear surface of the strike surface in a direction parallel to the rear surface of the strike surface; The insert is The front of the insert and The rear of the insert; An insert lock flange; Equipped with the insert is configured to be received within the back cavity; the insert locking flange is configured to be received within the locking groove; the insert forward surface is configured to be directly adjacent to and conform to the strike face aft surface; The insert rear portion further comprises: An upper part and Muscle back section and a transition portion between the upper portion and the muscle back portion; Equipped with the muscle back portion surrounds a void; the void defines a void central axis; an air gap angle is defined between a central axis of the air gap and a ground plane when the iron-type golf head is in an address position; the gap angle is between 0 and 30 degrees; the main club body further comprising an opening in the heel end; the opening is a hole that opens onto the outer surface of the heel end and into the back cavity; the opening aligns with the gap when the insert is received in the back cavity; the weight is configured to be received within the gap through the opening; The weight has a toe end portion, a central portion, and a heel end portion, the weight includes a first weight material and a second weight material; the first weight material has a density less than the second weight material; the heel end portion includes the second weight material; the toe end portion includes the second weight material; an iron-type golf club head, wherein the opening is closed by the cap after the weight is received in the cavity;

17. 17. The iron-type golf club head of claim 16, wherein the gap angle is between 10 and 20 degrees.

18. 17. The iron-type golf club head of claim 16, wherein the gap angle is between 5 and 15 degrees.

19. 17. The iron-type golf club head of claim 16, wherein the gap has a length between 50.8 millimeters and 101.6 millimeters.

20. 17. The iron-type golf club head of claim 16, wherein the void has a diameter between 6.35 millimeters and 19.05 millimeters.

Images