Co-Forged Iron Club Head With Monolithic Weight Encapsulation
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Solution Overview
Problem
Current golf club head manufacturing methods require post-manufacturing operations like machining, welding, and gluing 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 the golf club head after the body has been formed through machining cavities and secondary operations, then the mass properties and forgiveness can be adjusted, but the tolerances at the interfaces between different materials deteriorate and the feel of the club head is compromised
Solution Approach 1:
The patent applies preliminary action by pre-forming the billet with cavities before the main forging process. The cavities are created in the blank stage, and the secondary materials are positioned within these pre-prepared cavities before the final forging operation encases them monolithically. This sequence ensures that all materials are integrated in a single forging operation, eliminating post-manufacturing interface tolerance issues while maintaining the ability to adjust mass properties through strategic material placement.
2Adaptability or versatility
If multiple post-manufacturing operations such as machining, welding, and gluing are used to incorporate secondary materials, then the golf club head can achieve desired weight distribution and performance characteristics, but the manufacturing cost increases and the process becomes more complex
Solution Approach 1:
The patent merges multiple manufacturing operations into a single co-forging process. Instead of separately machining cavities, positioning secondary materials, welding, and gluing in sequential steps, the invention combines all these functions into one integrated forging operation. The pre-form billet with cavities is forged in a single operation that simultaneously shapes the club head body and monolithically encases the secondary materials, dramatically simplifying the manufacturing process while maintaining precise weight distribution control.
3Adaptability or versatility
If secondary materials are attached after the golf club head is formed, then the Moment of Inertia and Center of Gravity can be optimized for forgiveness, but the feel of the club head is compromised due to the introduction of multiple components and attachment operations
Solution Approach 1:
The patent employs composite materials by integrating secondary materials with different densities into the club head body through co-forging. High-density materials are strategically placed in specific cavities to optimize the Moment of Inertia and Center of Gravity for enhanced forgiveness. The monolithic encasement of these composite materials during the forging process ensures they become an integral part of the club head structure, maintaining a unified feel without the compromise associated with attached components.
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 internal cavities and weight adjustment portions that improve the inertial and performance attributes of the iron type golf club head.