Co-Forged Golf Club Head for Monolithic Weight Integration
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Solution Overview
Problem
Current golf club head manufacturing methods require post-manufacturing operations like machining, welding, and swaging to incorporate multiple materials, leading to tolerances issues and a compromised feel due to the introduction of secondary materials, which are costly and difficult to maintain.
Innovation Solution
A co-forged golf club head is created using a pre-form billet with cavities filled with different materials, then forged to encase weight adjustment portions monolithically within the body, eliminating the need for secondary attachment operations and maintaining a solid feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple materials are incorporated into a golf club head using traditional manufacturing methods, then mass properties and performance can be adjusted, but manufacturing complexity and post-processing operations increase
Solution Approach 1:
The patent combines multiple materials (steel and ductile iron) into a single co-forged golf club head body, eliminating the need for separate components that would require welding or other secondary attachment operations. The materials are integrated during the forging process itself, merging the benefits of material versatility with manufacturing simplicity.
Solution Approach 2:
The patent uses a composite construction with a steel shell and ductile iron interior, creating a multi-material golf club head that achieves desired mass properties and performance characteristics while being manufactured as a single integrated piece through co-forging, avoiding complex post-manufacturing operations.
2Adaptability or versatility
If multiple materials are used in a golf club head, then performance and mass properties can be optimized, but manufacturing precision and tolerances become more difficult to maintain
Solution Approach 1:
By merging the multiple materials into a single co-forged component rather than assembling separate parts, the patent eliminates interface tolerances and alignment issues that would arise from welding or mechanical attachment, maintaining manufacturing precision while achieving performance optimization.
Solution Approach 2:
The patent performs the material integration during the initial forging process rather than as a subsequent operation. The steel shell and ductile iron interior are positioned and bonded together before final shaping, ensuring precise tolerances are achieved during the primary manufacturing step rather than requiring complex post-processing to correct alignment issues.
3Adaptability or versatility
If traditional manufacturing methods are used with multiple materials, then material versatility is achieved, but production time and manufacturing cost increase
Solution Approach 1:
The patent merges the formation of multiple material components into a single co-forging operation, eliminating sequential manufacturing steps such as separate casting, machining, and welding operations. This integration maintains material versatility while significantly improving production efficiency by reducing the total number of manufacturing steps.
Solution Approach 2:
The patent performs material integration and component formation in advance during the co-forging process, rather than requiring subsequent assembly operations. The steel shell and ductile iron interior are positioned and bonded together during the primary manufacturing step, eliminating time-consuming post-processing operations and improving overall production efficiency.
Data Source
AI summary
A co-forged iron type golf club is disclosed. More specifically, the present invention discloses a co-forged iron type golf club with the body portion made out of a first material and at least one weight adjustment portion monolithically encased within the body portion of the co-forged iron type golf club head without the need for secondary attachment or machining operations. The present invention also includes a combination of lightweight and heavy density weight adjustment portions that could be introduced towards the final forging step of the co-forging process, allowing for more flexibility in the selection of materials.