US20130288823A1 - Co-forged golf club head and method of manufacture - Google Patents
Co-forged golf club head and method of manufacture Download PDFInfo
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- US20130288823A1 US20130288823A1 US13/927,764 US201313927764A US2013288823A1 US 20130288823 A1 US20130288823 A1 US 20130288823A1 US 201313927764 A US201313927764 A US 201313927764A US 2013288823 A1 US2013288823 A1 US 2013288823A1
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- United States
- Prior art keywords
- golf club
- club head
- weight adjustment
- forging
- adjustment portion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K17/00—Making sport articles, e.g. skates
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/0416—Heads having an impact surface provided by a face insert
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/0433—Heads with special sole configurations
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/047—Heads iron-type
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/003—Selecting material
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B2053/0491—Heads with added weights, e.g. changeable, replaceable
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B2209/00—Characteristics of used materials
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- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B60/00—Details or accessories of golf clubs, bats, rackets or the like
- A63B60/02—Ballast means for adjusting the centre of mass
Definitions
- the present invention relates generally to a co-forged golf club head formed from two or more materials and the method of manufacture for such a golf club head. More specifically, the present invention relates to the creation of an iron type golf club head from a pre-form billet that already contains two or more materials before the actual forging process; resulting in a multi-material golf club head that doesn't require any post manufacturing operations such as machining, welding, swaging, gluing, and the like.
- U.S. Pat. No. 4,523,759 to Igarashi discloses a perimeter weighted hollow golfing iron having a foam core with an effective hitting area concentrated toward the center of moment in an attempt to help make the game of golf easier. Distributing the weight of a golf club to the perimeter allow the moment of inertia (MOI) of a golf club head to be increased, reducing the undesirable twisting a golf club as it impacts a golf ball.
- MOI moment of inertia
- U.S. Pat. No. 4,809,977 to Doran et al. shows another example of an attempt to increase the moment of inertia of a golf club head by placing additional weights at the heel and toe portion of the golf club head.
- This increase in the moment of inertia of the golf club head achievable by increased heel and toe weighting could further prevent the golf club from twisting in a heel and toe direction, which mitigates the undesirable effect of sending a golf ball off the intended trajectory.
- U.S. Pat. No. 5,885,170 to Takeda shows the advantage of using multi-materials to create more extreme adjustment of the mass properties. More specifically, U.S. Pat. No. 5,885,170 teaches a body having a face formed of one material while a hosel is formed from another material having different specific gravity from that of the head body.
- U.S. Pat. No. 6,434,811 to Helmstetter et al. shows another example of utilization of multiple materials to improve the performance of a golf club head by providing a golf club head with a weighting system that is incorporated after the entirety of the golf club head has been formed.
- U.S. Pat. No. 7,938,739 to Cole et al. discloses a golf club head with a cavity integral with the golf club head, wherein the cavity extends from the heel region to the toe region; extending along a lower portion of the back face of the golf club head; extends approximately parallel to the strike face; and is approximately symmetrical about a centerline that bisects the golf club head between the heel region and the toe region.
- U.S. Pat. No. 6,095,931 to Hettinger et al. identifies this specific undesirable side effect of sacrifice in the feel by the usage of multiple different components.
- U.S. Pat. No. 6,095,931 addresses this issue by providing an isolation layer between the golf club head and the main body portion that comprises the striking front section.
- U.S. Pat. No. 7,828,674 to Kubota recognizes the severity of this problem by stating that hollow golf club heads having viscoelastic element feels light and hollow to the better golfer, hence they do not prefer such a golf club.
- U.S. Pat. No. 7,828,674 address the deficiencies of such a multi-material golf club by incorporating a block of magnesium to be embedded and or press-fitted into the recess formed in the metal only to be sealed with a metallic cover.
- a forged golf club head comprising a body portion having a striking surface made out of a first material, and at least one weight adjustment portion made out of a second material encased within the body portion; wherein the at least one weight adjustment portion is encased monolithically within the body portion of the golf club head without any secondary attachment operations.
- a method of forging a golf club head comprising of the steps of creating a cylindrical billet out of a first material, machining one or more cavities within the cylindrical billet, partially filling the one or more cavities with a second material to create a weight adjustment portion, filling the remaining volume of the one or more cavities with the first material to encase the weight adjustment portion, and forging the cylindrical billet to create a body portion of the golf club head; wherein the body portion monolithically encases the weight adjustment portion within a body of the golf club head without any secondary attachment operations.
- a forged golf club head comprising a body portion having a striking surface made out of first material, and at least one weight adjustment portion made out of a second material encased within the body portion; wherein the at least one weight adjustment portion is encased monolithically within the body portion without any secondary attachment operations.
- the first material has a first flow stress at a first forging temperature and the second material has a second flow stress at a second forging temperature, wherein the first flow stress and the second flow stress are substantially similar to one another, and the first forging temperature and the second forging temperature are substantially similar to one another and the first forging temperature and the second forging temperature are substantially similar to one another.
- the first material has a first thermal expansion coefficient and the second material has a second thermal expansion coefficient, wherein the first thermal expansion coefficient is greater than or equal to the second thermal expansion coefficient.
- FIG. 1 of the accompanying drawings shows a perspective view of a co-forged golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 2A-2D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 3A-3D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 4A-4D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 5A-5D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIG. 6 shows an exploded rear perspective view of a golf club head created using a multi-step co-forging method in accordance with a further alternative embodiment of the present invention
- FIG. 7 shows an exploded frontal perspective view of a golf club head created using a multi-step co-forging method in accordance with a further alternative embodiment of the present invention
- FIG. 8 shows a pre-formed billet used in a multi-step co-forging method to create a golf club head in accordance with an alternative embodiment of the present invention
- FIG. 9 shows a bent pre-formed billet during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention.
- FIGS. 10 a and 10 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIG. 11 a and 11 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIGS. 12 a and 12 b shows a rear and frontal exploded view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIGS. 13 a and 13 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention.
- FIGS. 14 a and 14 b shows a rear and frontal view of a finished golf club head after the multi-step co-forging in accordance with an alternative embodiment of the present invention
- FIG. 1 of the accompanying drawings shows a perspective view of a golf club head 100 in accordance with an exemplary embodiment of the present invention.
- the golf club head 100 shown in FIG. 1 may generally comprise of a body portion 102 and a hosel portion 104 , with the body portion 102 having several individually identifiable components such as a topline portion 106 , a sole portion 108 , a heel portion 110 , and a toe portion 112 .
- the golf club head 100 in accordance with an exemplary embodiment of the present invention may generally be comprised of at least one weight adjustment portion that is encased within the body portion 102 of the golf club head 100 .
- the weight adjustment portion may be monolithically encased within the body portion 102 to ensure that the weight adjustment portion is secured within the body portion 102 without departing form the scope and content of the present invention. Because the weight adjustment portion is monolithically encased within the body portion 102 of the golf club head 100 , these weights are not visible in FIG. 1 of the accompanying drawings. However, these weight adjustment portions will be shown in more detail in later figures, when various different views are presented.
- “Monolithically encased”, as referred to in the current patent application, may generally be defined as a having a specific internal component placed inside a separate external component without joints or seams in the finished product.
- having weight adjustment portions “monolithically encased” within the body portion 102 of the golf club head 100 may generally refer to the ability to have weight adjustment portions placed inside the body portion 102 of the golf club head without joints or seams that are generally required by post manufacturing processes such as milling, welding, brazing, gluing, or swaging.
- a weight that is “monolithically encased” within the current definition of the present invention could potentially have certain aspect of the internal weights exposed in the finish product to illustrate the existence of a weight adjustment portion without departing from the scope and content of the present invention. More specifically, “monolithically encased” refers to the methodology used to create the ultimate product as described above, and may not necessarily be limited to visually concealing the weight adjustment member.
- FIGS. 2A-2D illustrate the methodology used to create a co-forged golf club head 200 in accordance with an exemplary embodiment of the current invention. More specifically, FIGS. 2A-2D illustrate the steps involved in the forging of a golf club head from its rudimentary billet 201 shape into the final product of a golf club head 200 .
- FIG. 2A shows a pre-formed billet 201 in accordance with an exemplary embodiment of the present invention.
- the pre-form billet 201 may generally begin as a cylindrical rod formed from a first material, as it is common with the forging of a golf club head 200 .
- one or more cavities 216 are machined into the pre-form billet 201 .
- two cavities 216 are machined into the terminal ends of the pre-form billet 201 .
- the location and geometry of the cavities 216 within the pre-form billet 201 are important, as it correlates directly with the ultimate location of the weight adjustment portion 215 in the golf club head 200 after forging.
- the cavities 216 are partially filled with a second material that has a density different from the density of the first material in order to create the weight adjustment portion. 215 .
- the location, size, and shape of the weight adjustment portion 215 is just as critical as the location, size, and shape of the cavities 216 , as the weight adjustment portion 215 within the pre-form billet 201 correlates with the ultimate resting place of the weight adjustment portion 215 in the golf club head.
- FIG. 2C shows the final phase of the pre-form billet 201 as the remaining volume of the cavities 216 are filled with the first material and sealed through traditional joining methods such as welding, brazing, and swaging. Sealing the cavities 216 allows the weight adjustment portion 215 to be monolithically encased within the body of the pre-form billet 201 , which will allow the same weight adjustment portion 215 to be monolithically encased in the body 202 of the golf club head 200 after the forging process. After the cavities 216 are filled, the pre-form billet 201 is subjected to the normal forging process associated with the forging of a golf club head 200 .
- the above discussion regarding the forging of a golf clubs incorporated by reference do a good job describing the actual forging process, it fails to address the additional concerns with the co-forging process of the current invention wherein two different materials are involved in this forging process. More specifically, because a weight adjustment portion 215 is made out of a second material that could be different from the first material used to create remainder of the pre-form billet 201 , special care must be taken to ensure that the different materials can be forged together to form a golf club head 200 . Hence, in order to select two cohesive materials that are capable of being co-forged together, the first material and the second material may generally have to have very specific material properties requirements with respect to their flow stress and their thermal expansion coefficient. Although it is most preferential for the two materials to have identical material properties yielding in consistency in forging, the usage of identical materials may not offer any weight adjustment benefits required for the basis of the current invention.
- Flow stress of a material may generally be defined as the instantaneous value of stress require for continued deforming the material (i.e. to keep the metal flowing); and the creation of a cohesive forged component from two different materials will require them to flow at relatively the same speed when subjected to the stresses of the forging process. It is commonly known that the flow stress of a material is generally a function of the yield strength, the flow stress of a material may generally be summed up by Eq. (1) below.
- a first flow stress of the first material at its first forging temperate is substantially similar but not identical to the second flow stress of the second material at its second forging temperature; with the first forging temperature and the second forging temperature being substantially similar.
- the first material may be 1025 steel having a first flow stress of about 10 ksi (kilo-pound per square inch) at a forging temperature of about 1,200° C.
- the second material may a Niobium material having a second flow stress of also about 12 ksi at a forging temperature of about 1,100° C.
- the first material may be a 1025 steel and the second material may be a Niobium material
- various other materials may also be used without departing from the scope and content of the present invention so long as their flow stresses are similar at a similar forging temperature.
- any two materials may be used in the current co-forging process so long as the second flow stress is no more than 20% greater or no less than 20% lesser than the first flow stress.
- the thermal expansion coefficient of the first and second materials are also important to the proper co-forging of two distinct materials. More specifically, a first thermal expansion coefficient of the first material may generally need to be greater than or at least equal to the second thermal expansion coefficient of the second material. Because the thermal expansion coefficient also relate to the shrinkage of the material after forging, it is important that the first material that monolithically encases the second material have a higher thermal expansion coefficient to prevent gaps from forming at the interface portion of the materials.
- the first material may be 1025 steel having a thermal expansion coefficient of about 8.0 ⁇ in/in ° F.
- the second material may be Niobium having a second thermal expansion coefficient of about 3.94 ⁇ in/in ° F.
- the second thermal expansion coefficient is smaller than the first thermal expansion coefficient
- the numbers can be identical to achieve perfect mating of the two materials without departing from the scope and content of the present invention.
- the second material could be made out of a 6-4 Titanium material to reduce the weight of the weight adjustment portion 215 .
- the Titanium material may generally have a flow stress of about 10 ksi at a forging temperature of about 1,100° C. and a thermal expansion coefficient of about 6.1 ⁇ in/in ° F.
- FIG. 2D of the accompanying drawings shows a perspective view of a finished golf club head 200 created using the co-forging process above, wherein the golf club head 200 monolithically encases at least one weight adjustment portion 215 within the body portion 202 . More specifically, in the current exemplary embodiment of the present invention, the weight adjustment portions 215 are placed near a heel portion 210 and a toe portion 212 of the golf club head 200 .
- the placement of the weight adjustment portion 215 near a heel portion 210 and the toe portion 212 allow the golf club head 200 to have an increase in the Moment of Inertia (MOI) without the need for any secondary attachment operations; which will result in a more consistent feel upon impact with a golf ball.
- MOI Moment of Inertia
- the exact placement of the weight adjustment portion 215 within the body portion 202 of the golf club head 200 is slightly different in every single different club head, this is the outcome of the current inventive co-forging process involves different materials. More specifically, the exact placement of the weight adjustment portion 215 may differ with each single golf club 200 , as the flow stress of the first material and the second material will help determine the final location of the weight adjustment portion 215 .
- the interface between the weight adjustment portion 215 and the body portion 202 of the golf club head 200 may generally be an irregular interface, with the boundaries jagged to indicate that the entire golf club head 200 has been co-forged. This is dramatically different from a cavity created via a post machining secondary operations such as milling and drilling; which generally have clean bifurcation lines of the two different materials.
- FIGS. 3A-3D of the accompanying drawings shows an alternative embodiment of the present invention wherein two separate weight adjustment portions 314 and 315 are placed at different portions of the pre-form billet 301 to create a golf club head 300 with a different performance criteria. More specifically, the golf club head 300 shown in FIG. 3D may have a lightweight weight adjustment portion 314 near a topline portion 306 of the golf club head 300 and a heavyweight weight adjustment portion 315 near a sole 308 of the golf club head 300 to help shift the Center of Gravity (CG) of the golf club head 300 lower to help with launch and spin characteristics of the current inventive golf club head 300 .
- CG Center of Gravity
- FIG. 3A-3C similar to before, show the formation process of the current inventive golf club head 300 , starting from a pre-form billet 301 . More specifically, FIG. 3A shows a perspective view of a pre-form billet 301 in accordance with an exemplary embodiment of the present invention wherein a plurality of cavities 316 are drilled at strategic locations within the billet 301 .
- the plurality of cavities 316 are drilled near a top portion and a bottom portion of the pre-form billet 301 instead of at each of the terminal ends, as this specific embodiment focuses on lowering the CG of the golf club head 300 by removing weight from the top line portion 306 of the golf club head 300 and shifting it towards a sole portion 308 of the golf club head 300 .
- FIG. 3B of the accompanying drawings shows two weight adjustment portions 314 and 315 being placed inside the cavities 316 created in FIG. 3A .
- top cavity 316 can not be left completely blank in this current embodiment of the present invention, as the entire pre-form billet 301 will eventually be forged into the shape of a golf club head 300 , causing any empty cavity 316 to collapse upon itself.
- the top cavity 316 may be filled with a lightweight weight adjustment portion 314
- the lower cavity 316 may be filled with a heavyweight weight adjustment portion 315 .
- the lightweight weight adjustment portion 314 may generally be made out of a third material having a third density, wherein the heavyweight weight adjustment portion 315 may generally be made out of second material having a second density.
- the third density may generally be less than about 7.0 g/cc, wherein the second density may generally be greater than about 7.8 g/cc; while the first material used to form the body portion 302 of the golf club head 300 may generally have a first density of about 7.8 g/cc.
- FIG. 3C of the accompanying drawings shows the final stage of the pre-form billet 301 that has monolithically encased the weight adjustment portions 314 and 315 within the internal cavities 316 of the pre-form billet 301 .
- the creation of the pre-form billet shown in FIG. 3C involves filling in the remaining volume of the cavities 316 with a first material to encase the weight adjustment portions 315 and 316 within the pre-form billet 301 .
- the pre-form billet 301 is subsequently forged to create a golf club head 300 as shown in FIG. 3D , wherein the weight adjustment portions 314 and 315 are monolithically encased within the body portion 302 of the golf club head 300 .
- the third material may generally need to have a third flow stress that is similar with the first flow stress of the first material and a third thermal expansion coefficient less than the first thermal expansion coefficient of the first material. More specifically, in one exemplary embodiment of the present invention, the third material may be a 6-4 Titanium material having a third flow stress of about 10 ksi at a forging temperature of about 1,100° C. and a third thermal expansion coefficient of about 6.1 ⁇ in/in ° F.
- FIGS. 2A-2D and FIGS. 3A-3D show different embodiments of the present invention used to achieve a higher MOI and a lower CG respectively, these features are not mutually exclusive from one another.
- FIGS. 4A-4D features may be taken from both embodiments discussed above to create a co-forged golf club head with a higher MOI as well as a lower CG all without departing from the scope and content of the present invention. More specifically, in FIGS.
- FIG. 5A-5D of the accompanying drawings shows a further alternative embodiment of the present invention wherein the body portion 502 of the golf club head 500 may be comprised of a monolithically encased weight adjustment portion 514 .
- the weight adjustment portion 514 may be relatively large in size, allowing it to replace a majority of the body portion 502 of the golf club head 500 once the forging process is completely.
- the monolithically encased weight adjustment portion 514 may generally be made out of a third material having a third density that is significantly lower than the first density of the first material used to form the body portion 502 of the golf club head 500 ; allowing weight to be taken out from the body portion 502 of the golf club head 500 . Because the lightweight third material used to form the weight adjustment portion 514 may generally be relatively soft compare to the first material, it is generally desirable to monolithically encase the weight adjustment portion 514 within the internal body of the golf club head 500 , allowing significant weight savings to be achieved without sacrificing feel.
- FIG. 5A of the accompanying drawings shows a pre-form billet 501 similar to the previous figures.
- the cavity 506 is significantly larger within the pre-form billet 501 itself.
- This large cavity 506 can then be used in FIG. 5B to be filled with a weight adjustment portion 514 to adjust the weight, density, and overall feel of the golf club head 500 .
- FIG. 5C similar to described above, the remaining volume of the cavity 516 is filled with the original first material before the entire pre-form billet 501 is subjected to the forging process to create a golf club head 500 .
- the hosel portion 504 of the golf club head 500 is deliberately made from the conventional first material, as the bending characteristics of the second material used to form the weight adjustment portion 514 may generally not be suitable for the bending requirements of an iron type golf club head 500 .
- the third material used to form the weight adjustment portion 514 could be a lightweight iron-aluminum material having a density of less than about 7.10 g/cc, more preferably less than about 7.05 g/cc, and most preferably less than about 7.00 g/cc, all without departing from the scope and content of the present invention.
- numerous other materials can also be used as the third material used to form the weight adjustment portion 514 without departing from the scope and content of the present invention so long as the third material has a density within the range described above.
- FIG. 6 of the accompanying drawings shows an exploded rear perspective view of a golf club head 600 in accordance with a further alternative embodiment of the present invention utilizing a multi-step co-forging process.
- This multi-step co-forging process allows for an improvement in the ability to precisely place different weight members within different parts of the golf club head 600 .
- This improvement in the ability to precisely place weighting members not only opens the door to allow multiple different materials to be forged together that were previously impossible due to their inherent material limitations, but it also allows for more improvements in the performance characteristics of a golf club 600 than previously discussed.
- FIG. 6 of the accompanying drawings shows a co-forged golf club head 600 created using the multi-step co-forging process.
- the golf club head 600 have heavier density weight adjustment portions 615 at the heel 610 and toe 612 portion of the golf club head 600 corresponding to their respective cavities 616 .
- the weight adjustment portions 615 are then combined with caps 617 to retain the weight adjustment portions 615 together with the body of the golf club head 600 during the co-forging process.
- the current exemplary golf club head 600 utilizes a multi-step co-forging process to install the heavy weight adjustment portions 615 without the need of post manufacturing finishes such as welding, brazing, swaged, or the like.
- the benefit of utilizing such a co-forged process is the uniformity and consistency of the material, resulting in superior performance and feel.
- the current embodiment of the present invention allows the heavy weight adjustment portions 615 to be placed at the extremities of the golf club head 600 , further improving the center of gravity location as well as the moment of inertia of the golf club head 600 .
- FIG. 7 of the accompanying drawings shows an exploded frontal perspective view of a golf club head 700 in accordance with a further alternative embodiment of the present invention. More specifically, golf club head 700 incorporates a lightweight weight adjustment portion 714 behind a striking face 718 portion of the golf club head 700 within a cavity 716 in a multi-step co-forging process.
- the location and placement of the lightweight weight adjustment portion 714 can be more precisely placed, hence creating the opportunity to reduce weight from the striking face 718 portion of the golf club head 700 .
- FIGS. 8-14 have been presented below, detailing the steps involved in this multi-step co-forging process.
- FIG. 8 of the accompanying drawings similar to FIGS. 2-5 above, show a pre-form billet 801 used to create a forged golf club head.
- This forged billet 801 is then bent to an L-shape as shown in FIG. 9 to prepare the billet 901 for the die that begins the forging process.
- FIGS. 10 a and 10 b shows the frontal and rear view of a golf club head 1000 that's been subjected to the first step of the multi-step co-forging process. In this preliminary step, the billet has been forged to a shape that roughly resembles that of a golf club head 1000 .
- the shape of the golf club 1000 can be seen, as it already has a hosel portion 1004 , a heel portion 1010 , and a toe portion 1012 .
- preliminary imprints of the cavity 1016 can already be seen in the heel 1010 and toe 1012 portion of the golf club head; while in the frontal view of the golf club head 1000 shown in FIG. 10 b , the cavity 1016 can already be seen near the striking face.
- the excess trim 1030 may be removed from the golf club head 1000 and subsequent to that, subjected to another rough forging step.
- the excess material may flow outside of the confines of the die, resulting in what is commonly known as “flash”. This flash material, as previously discussed, may be trimmed off in between the individual multi-forging steps to improve the adherence to the die in subsequent steps.
- FIGS. 11 a and 11 b The results of this secondary forging step can be shown in FIGS. 11 a and 11 b .
- the golf club head 1100 in this current state is starting to take on a shape that more closely resembles that of a finished product.
- the boundaries and shapes of the cavities 1116 are also starting to take on their respective shape as well.
- the weight adjustment portions can be added into the specific cavities 1116 before the golf club head 1100 is subjected to the final forging step.
- FIGS. 12 a and 12 b The relationship between the weight adjustment portions to the cavities 1116 on the golf club head 1100 can be shown more clearly in FIGS. 12 a and 12 b .
- the cavity 1216 on the rear portion of the golf club head 1200 may be filled with weight adjustment portions 1215 that may generally have a higher density than the body of the golf club head 1200 .
- the high density weight adjustment portions 1215 may then be covered up with a cap 1217 made out of a similar material as the body of the golf club head 1200 , allowing high density weight adjustment portions 1215 to be retained within the cavity 1216 .
- the cavity 1216 may be filled with a weight adjustment member 1214 having a lower density than the body portion of the golf club head 1200 . Similar to the rear, this weight adjustment portion 1214 may be secured in the cavity 1216 with a cap like mechanism that also serves as a striking face 1218 .
- the striking face 1218 similar to the cap 1217 , may be made out of a similar material as the body of the golf club head 1200 . Having the cap 1217 and the striking face 1218 be made out of the same material as the remainder of the body of the golf club head 1200 is beneficial because it allows these two components to be welded to the body portion of the golf club head 1200 . Having these components welded in place allows the weight adjustment portions 1215 to be secured within their own respective cavities 1216 before the final forging step that completes the current multi-step co-forging process.
- the cap 1217 may not even be necessarily needed to completely cover up the cavity 1216 and the weight adjustment member 1214 . In fact, in an alternative embodiment of the present invention, the cap 1217 only needs to partially cover the weight adjustment portion 1215 to a degree that sufficiently prevents the weight adjustment portion 1215 from separating from the body of the golf club head 1200 .
- the final forging process involved in this process is generally creates a golf club head 1200 that can be considered “co-forged”, as now the golf club head 1200 contains two or more different materials being forged together in this final step.
- FIGS. 13 a and 13 b show the results of the golf club head 1300 after it has completed the final co-forging step.
- the golf club head 1300 In its current state, the golf club head 1300 has taken its final shape, and the weight adjustment members 1316 and 1314 are all now monolithically enclosed within their respective cavities by the caps 1317 and striking face plate 1318 .
- the golf club head 1300 may have taken their form, there are still excessive flash 1330 around the perimeter of the golf club head 1300 that needs to be trimmed before the golf club head 1300 takes its final form.
- FIGS. 14 a and 14 b show the completed golf club head 1400 as a result of this co-forging process.
- the excess flash 1330 has already been trimmed, improving the aesthetic appeal of the golf club head 1400 .
- the weight adjustment portions 1416 and 1418 are seamlessly and monolithically encased with the body of the golf club head 1400 via the cap 1417 and the striking face plate 1318 .
- the advantage of having the weight adjustment portions 1416 seamlessly and monolithically encased with the body of the golf club head 1400 via this co-forged process is that it prevents rattling, and improves the solid feel of the golf club head 1400 .
- the present golf club head can achieve a feel that is almost non-discernible from a unitary forged golf club head utilizing conventional forging methodologies.
- this present multi-step co-forging methodology creates a unique relationship between the weight adjustment portions 1416 and 1418 and the cavity 1216 (see FIG. 12 ) that it sits in. More specifically, it can be said that the outer surface area of the weight adjustment portion 1416 may generally be identical to the inner surface area of the cavity 1216 .
- the cavity 1216 may generally include the surface area of any caps 1217 or face plate 1218 used to complete the cavity 1216 created by the rough forging steps. (See FIG.
- the current multi-step co-forging process may differ from the pure co-forging process in that it no longer requires the two materials to have similar flow stresses between the different materials. This elimination of the requirement that the material needs to have similar flow stresses may be beneficial because it allows a wider range of materials to be used, especially when it comes to exotic materials providing extreme weighting benefits such as Tungsten.
- the current multi-step co-forging process is capable of achieving this by forging the cavity for the weight before using a final cap type material to fill the gap around the cavity to completely enclose the weight adjustment portion within the cap type material.
- the need for the second material to have a smaller thermal expansion coefficient as the first material still stands true in this multi-step co-forging process. This requirement still stands because the second material, although encompassed in a cavity via a cap, is still subjected to the same forging temperature as the external first material. Any excessive expansion of the second material would degrade the structural rigidity of the cap, causing potential failures in the bonding process.
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Abstract
Description
- The present application is a Continuation-In-Part of U.S. patent application Ser. No. 13/305,087, filed on Nov. 28, 2011, the disclosure of which is incorporated by reference in its entirety.
- The present invention relates generally to a co-forged golf club head formed from two or more materials and the method of manufacture for such a golf club head. More specifically, the present invention relates to the creation of an iron type golf club head from a pre-form billet that already contains two or more materials before the actual forging process; resulting in a multi-material golf club head that doesn't require any post manufacturing operations such as machining, welding, swaging, gluing, and the like.
- Golf is hard! When your average golfer swings a golf club, he or she may have dramatic variations in his or her golf swing, resulting in numerous off-center hits, which result in diminished performance when compared to a direct center hit. However, in an attempt to make this very difficult game more enjoyable for the average golfer, golf club designers have came up with unique golf club designs that will mitigate the harsh realities of a less than perfect golf swing.
- In one early example, U.S. Pat. No. 4,523,759 to Igarashi discloses a perimeter weighted hollow golfing iron having a foam core with an effective hitting area concentrated toward the center of moment in an attempt to help make the game of golf easier. Distributing the weight of a golf club to the perimeter allow the moment of inertia (MOI) of a golf club head to be increased, reducing the undesirable twisting a golf club as it impacts a golf ball.
- U.S. Pat. No. 4,809,977 to Doran et al. shows another example of an attempt to increase the moment of inertia of a golf club head by placing additional weights at the heel and toe portion of the golf club head. This increase in the moment of inertia of the golf club head achievable by increased heel and toe weighting could further prevent the golf club from twisting in a heel and toe direction, which mitigates the undesirable effect of sending a golf ball off the intended trajectory.
- Although the initial attempts at increasing the forgiveness and playability of a golf club for an average golfer are admirable, it does not take advantage of the extreme forgiveness that can be achievable by utilizing different materials to form different portions of the golf club head. In one example, U.S. Pat. No. 5,885,170 to Takeda shows the advantage of using multi-materials to create more extreme adjustment of the mass properties. More specifically, U.S. Pat. No. 5,885,170 teaches a body having a face formed of one material while a hosel is formed from another material having different specific gravity from that of the head body. U.S. Pat. No. 6,434,811 to Helmstetter et al. shows another example of utilization of multiple materials to improve the performance of a golf club head by providing a golf club head with a weighting system that is incorporated after the entirety of the golf club head has been formed.
- More recently, the improvements in incorporating multi-materials into a golf club head has matured significantly by incorporating numerous multiple materials of different characteristics by machining cavities into the golf club head. More specifically, U.S. Pat. No. 7,938,739 to Cole et al. discloses a golf club head with a cavity integral with the golf club head, wherein the cavity extends from the heel region to the toe region; extending along a lower portion of the back face of the golf club head; extends approximately parallel to the strike face; and is approximately symmetrical about a centerline that bisects the golf club head between the heel region and the toe region.
- However, as multiple materials are introduced into the golf club after the body has been completed, the tolerances of the interfaces between the different materials could potentially cause undesirable side effects of altering the feel of the golf club head. U.S. Pat. No. 6,095,931 to Hettinger et al. identifies this specific undesirable side effect of sacrifice in the feel by the usage of multiple different components. U.S. Pat. No. 6,095,931 addresses this issue by providing an isolation layer between the golf club head and the main body portion that comprises the striking front section.
- U.S. Pat. No. 7,828,674 to Kubota recognizes the severity of this problem by stating that hollow golf club heads having viscoelastic element feels light and hollow to the better golfer, hence they do not prefer such a golf club. U.S. Pat. No. 7,828,674 address the deficiencies of such a multi-material golf club by incorporating a block of magnesium to be embedded and or press-fitted into the recess formed in the metal only to be sealed with a metallic cover.
- Despite all of the above attempts to improve the performance of a golf club head all while trying to minimize the sacrifice in feel of a golf club, all of the methodologies require a significant amount of post manufacturing operation that creates cavities and recesses in the club head for the secondary material to be incorporated. These type of secondary operations are not only expensive, but the ability to maintain a tight enough tolerance between the various components make is very difficult to maintain the solid feel generally associated with an unitarily formed golf club head.
- Hence, it can be seen from above, despite all the development in creating a golf club head that's more forgiving without sacrificing the feel associated with a conventional club head, the current art is incapable of creating such a club without utilizing severe post manufacturing machining that causes bad feel.
- In one aspect of the present invention is a forged golf club head comprising a body portion having a striking surface made out of a first material, and at least one weight adjustment portion made out of a second material encased within the body portion; wherein the at least one weight adjustment portion is encased monolithically within the body portion of the golf club head without any secondary attachment operations.
- In another aspect of the present invention is a method of forging a golf club head comprising of the steps of creating a cylindrical billet out of a first material, machining one or more cavities within the cylindrical billet, partially filling the one or more cavities with a second material to create a weight adjustment portion, filling the remaining volume of the one or more cavities with the first material to encase the weight adjustment portion, and forging the cylindrical billet to create a body portion of the golf club head; wherein the body portion monolithically encases the weight adjustment portion within a body of the golf club head without any secondary attachment operations.
- In another aspect of the present invention is a forged golf club head comprising a body portion having a striking surface made out of first material, and at least one weight adjustment portion made out of a second material encased within the body portion; wherein the at least one weight adjustment portion is encased monolithically within the body portion without any secondary attachment operations. The first material has a first flow stress at a first forging temperature and the second material has a second flow stress at a second forging temperature, wherein the first flow stress and the second flow stress are substantially similar to one another, and the first forging temperature and the second forging temperature are substantially similar to one another and the first forging temperature and the second forging temperature are substantially similar to one another. The first material has a first thermal expansion coefficient and the second material has a second thermal expansion coefficient, wherein the first thermal expansion coefficient is greater than or equal to the second thermal expansion coefficient.
- These and other features, aspects and advantages of the present invention will become better understood with references to the following drawings, description and claims.
- The foregoing and other features and advantages of the invention will be apparent from the following description of the invention as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
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FIG. 1 of the accompanying drawings shows a perspective view of a co-forged golf club head in accordance with an exemplary embodiment of the present invention; -
FIGS. 2A-2D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention; -
FIGS. 3A-3D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention; -
FIGS. 4A-4D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention; -
FIGS. 5A-5D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention -
FIG. 6 shows an exploded rear perspective view of a golf club head created using a multi-step co-forging method in accordance with a further alternative embodiment of the present invention; -
FIG. 7 shows an exploded frontal perspective view of a golf club head created using a multi-step co-forging method in accordance with a further alternative embodiment of the present invention; -
FIG. 8 shows a pre-formed billet used in a multi-step co-forging method to create a golf club head in accordance with an alternative embodiment of the present invention; -
FIG. 9 shows a bent pre-formed billet during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention; -
FIGS. 10 a and 10 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention; -
FIG. 11 a and 11 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention; -
FIGS. 12 a and 12 b shows a rear and frontal exploded view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention; -
FIGS. 13 a and 13 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention; and -
FIGS. 14 a and 14 b shows a rear and frontal view of a finished golf club head after the multi-step co-forging in accordance with an alternative embodiment of the present invention; - The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
- Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address any or all of the problems discussed above or may only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below.
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FIG. 1 of the accompanying drawings shows a perspective view of agolf club head 100 in accordance with an exemplary embodiment of the present invention. Thegolf club head 100 shown inFIG. 1 may generally comprise of abody portion 102 and ahosel portion 104, with thebody portion 102 having several individually identifiable components such as atopline portion 106, asole portion 108, aheel portion 110, and atoe portion 112. Thegolf club head 100 in accordance with an exemplary embodiment of the present invention may generally be comprised of at least one weight adjustment portion that is encased within thebody portion 102 of thegolf club head 100. In a preferred embodiment, the weight adjustment portion may be monolithically encased within thebody portion 102 to ensure that the weight adjustment portion is secured within thebody portion 102 without departing form the scope and content of the present invention. Because the weight adjustment portion is monolithically encased within thebody portion 102 of thegolf club head 100, these weights are not visible inFIG. 1 of the accompanying drawings. However, these weight adjustment portions will be shown in more detail in later figures, when various different views are presented. - Before moving onto subsequent figures, it is worthwhile here to emphasize that the current
golf club head 100 is created using a forging process and the weights are incorporated without any post finish machining operations. This is an important distinction to establish because the same result of a monolithically encasing a weight adjustment portion is extremely difficult to achieve using alternative manufacturing processes such as casting. “Monolithically encased”, as referred to in the current patent application, may generally be defined as a having a specific internal component placed inside a separate external component without joints or seams in the finished product. With respect to the current invention, having weight adjustment portions “monolithically encased” within thebody portion 102 of thegolf club head 100 may generally refer to the ability to have weight adjustment portions placed inside thebody portion 102 of the golf club head without joints or seams that are generally required by post manufacturing processes such as milling, welding, brazing, gluing, or swaging. - It should also be noted here that a weight that is “monolithically encased” within the current definition of the present invention could potentially have certain aspect of the internal weights exposed in the finish product to illustrate the existence of a weight adjustment portion without departing from the scope and content of the present invention. More specifically, “monolithically encased” refers to the methodology used to create the ultimate product as described above, and may not necessarily be limited to visually concealing the weight adjustment member.
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FIGS. 2A-2D illustrate the methodology used to create a co-forgedgolf club head 200 in accordance with an exemplary embodiment of the current invention. More specifically,FIGS. 2A-2D illustrate the steps involved in the forging of a golf club head from itsrudimentary billet 201 shape into the final product of agolf club head 200. -
FIG. 2A shows apre-formed billet 201 in accordance with an exemplary embodiment of the present invention. As it can be seen fromFIG. 2A , thepre-form billet 201 may generally begin as a cylindrical rod formed from a first material, as it is common with the forging of agolf club head 200. In order to create aweight adjustment portion 215 that can be monolithically encased within thebody portion 202 of thegolf club head 200, one ormore cavities 216 are machined into thepre-form billet 201. In this current exemplary embodiment shown inFIG. 2A , twocavities 216 are machined into the terminal ends of thepre-form billet 201. The location and geometry of thecavities 216 within thepre-form billet 201 are important, as it correlates directly with the ultimate location of theweight adjustment portion 215 in thegolf club head 200 after forging. - Moving onto
FIG. 2B , it can be seen that once thecavities 216 are machined, thecavities 216 are partially filled with a second material that has a density different from the density of the first material in order to create the weight adjustment portion. 215. Similar to the discussion above, the location, size, and shape of theweight adjustment portion 215 is just as critical as the location, size, and shape of thecavities 216, as theweight adjustment portion 215 within thepre-form billet 201 correlates with the ultimate resting place of theweight adjustment portion 215 in the golf club head. - Finally,
FIG. 2C shows the final phase of thepre-form billet 201 as the remaining volume of thecavities 216 are filled with the first material and sealed through traditional joining methods such as welding, brazing, and swaging. Sealing thecavities 216 allows theweight adjustment portion 215 to be monolithically encased within the body of thepre-form billet 201, which will allow the sameweight adjustment portion 215 to be monolithically encased in thebody 202 of thegolf club head 200 after the forging process. After thecavities 216 are filled, thepre-form billet 201 is subjected to the normal forging process associated with the forging of agolf club head 200. Although the basic steps involved in forging agolf club head 200 are important to the understanding of the current invention, it involves a relatively archaic and established technique, which the present application will not dive into much detail. More information regarding the steps involved in the forging of a basic golf club head without monolithically encased weight adjustment portions can be found in U.S. Pat. No. 3,825,991 to Cornell, and U.S. Pat. No. 6,666,779 to Iwata et al., the disclosure of which are all incorporated by reference in its entirety. - Although the above discussion regarding the forging of a golf clubs incorporated by reference do a good job describing the actual forging process, it fails to address the additional concerns with the co-forging process of the current invention wherein two different materials are involved in this forging process. More specifically, because a
weight adjustment portion 215 is made out of a second material that could be different from the first material used to create remainder of thepre-form billet 201, special care must be taken to ensure that the different materials can be forged together to form agolf club head 200. Hence, in order to select two cohesive materials that are capable of being co-forged together, the first material and the second material may generally have to have very specific material properties requirements with respect to their flow stress and their thermal expansion coefficient. Although it is most preferential for the two materials to have identical material properties yielding in consistency in forging, the usage of identical materials may not offer any weight adjustment benefits required for the basis of the current invention. - First of, in order for metallic materials to have the capabilities of being co-forged together, the respective flow stress' of each of the materials needs to be properly considered. Flow stress of a material, may generally be defined as the instantaneous value of stress require for continued deforming the material (i.e. to keep the metal flowing); and the creation of a cohesive forged component from two different materials will require them to flow at relatively the same speed when subjected to the stresses of the forging process. It is commonly known that the flow stress of a material is generally a function of the yield strength, the flow stress of a material may generally be summed up by Eq. (1) below.
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Yf=Ken Eq. (1) - wherein
- Yf=Flow Stress (MPa)
- K=Strain Coefficient (MPa)
- N=Strain Hardening Exponent
- In addition to the above equation, it is worthwhile to mention here that the flow stress of a material may not be construed in vacuum, but rather, it is a function of the forging temperature of the material as well. Hence, in a current exemplary embodiment of the present invention, a first flow stress of the first material at its first forging temperate is substantially similar but not identical to the second flow stress of the second material at its second forging temperature; with the first forging temperature and the second forging temperature being substantially similar. More specifically, in a more detailed embodiment, the first material may be 1025 steel having a first flow stress of about 10 ksi (kilo-pound per square inch) at a forging temperature of about 1,200° C., while the second material may a Niobium material having a second flow stress of also about 12 ksi at a forging temperature of about 1,100° C.
- Although in the exemplary embodiment of the present invention described above, the first material may be a 1025 steel and the second material may be a Niobium material, various other materials may also be used without departing from the scope and content of the present invention so long as their flow stresses are similar at a similar forging temperature. Alternatively speaking, any two materials may be used in the current co-forging process so long as the second flow stress is no more than 20% greater or no less than 20% lesser than the first flow stress.
- As mentioned before, other than flow stress, the thermal expansion coefficient of the first and second materials are also important to the proper co-forging of two distinct materials. More specifically, a first thermal expansion coefficient of the first material may generally need to be greater than or at least equal to the second thermal expansion coefficient of the second material. Because the thermal expansion coefficient also relate to the shrinkage of the material after forging, it is important that the first material that monolithically encases the second material have a higher thermal expansion coefficient to prevent gaps from forming at the interface portion of the materials. In a more detailed embodiment of the present invention, the first material may be 1025 steel having a thermal expansion coefficient of about 8.0 μin/in ° F., while the second material may be Niobium having a second thermal expansion coefficient of about 3.94 μin/in ° F.
- It should be noted that although in the above exemplary embodiment the second thermal expansion coefficient is smaller than the first thermal expansion coefficient, the numbers can be identical to achieve perfect mating of the two materials without departing from the scope and content of the present invention. In fact, in one exemplary embodiment of the present invention, it may be preferred for the first material and the second material to have the same thermal expansion coefficient, as excessive shrinkage of the outer material upon the inner material could potentially create additional stresses at the interface portions of the two materials.
- Alternatively, in an attempt to provide different weighting characteristics, the second material could be made out of a 6-4 Titanium material to reduce the weight of the
weight adjustment portion 215. The Titanium material may generally have a flow stress of about 10 ksi at a forging temperature of about 1,100° C. and a thermal expansion coefficient of about 6.1 μin/in ° F. - Now that the forging process, and the specific concerns involving the co-forging of different materials have been discussed,
FIG. 2D of the accompanying drawings shows a perspective view of a finishedgolf club head 200 created using the co-forging process above, wherein thegolf club head 200 monolithically encases at least oneweight adjustment portion 215 within thebody portion 202. More specifically, in the current exemplary embodiment of the present invention, theweight adjustment portions 215 are placed near aheel portion 210 and atoe portion 212 of thegolf club head 200. The placement of theweight adjustment portion 215 near aheel portion 210 and thetoe portion 212 allow thegolf club head 200 to have an increase in the Moment of Inertia (MOI) without the need for any secondary attachment operations; which will result in a more consistent feel upon impact with a golf ball. - Before moving onto a discussion regarding different embodiments of the present invention, it is worthwhile here to note that the exact placement of the
weight adjustment portion 215 within thebody portion 202 of thegolf club head 200 is slightly different in every single different club head, this is the outcome of the current inventive co-forging process involves different materials. More specifically, the exact placement of theweight adjustment portion 215 may differ with eachsingle golf club 200, as the flow stress of the first material and the second material will help determine the final location of theweight adjustment portion 215. In addition to the above, it should be noted that the interface between theweight adjustment portion 215 and thebody portion 202 of thegolf club head 200 may generally be an irregular interface, with the boundaries jagged to indicate that the entiregolf club head 200 has been co-forged. This is dramatically different from a cavity created via a post machining secondary operations such as milling and drilling; which generally have clean bifurcation lines of the two different materials. -
FIGS. 3A-3D of the accompanying drawings shows an alternative embodiment of the present invention wherein two separateweight adjustment portions pre-form billet 301 to create agolf club head 300 with a different performance criteria. More specifically, thegolf club head 300 shown inFIG. 3D may have a lightweightweight adjustment portion 314 near atopline portion 306 of thegolf club head 300 and a heavyweightweight adjustment portion 315 near a sole 308 of thegolf club head 300 to help shift the Center of Gravity (CG) of thegolf club head 300 lower to help with launch and spin characteristics of the current inventivegolf club head 300. -
FIG. 3A-3C , similar to before, show the formation process of the current inventivegolf club head 300, starting from apre-form billet 301. More specifically,FIG. 3A shows a perspective view of apre-form billet 301 in accordance with an exemplary embodiment of the present invention wherein a plurality ofcavities 316 are drilled at strategic locations within thebillet 301. It should be noted that in this current exemplary embodiment the plurality ofcavities 316 are drilled near a top portion and a bottom portion of thepre-form billet 301 instead of at each of the terminal ends, as this specific embodiment focuses on lowering the CG of thegolf club head 300 by removing weight from thetop line portion 306 of thegolf club head 300 and shifting it towards asole portion 308 of thegolf club head 300. -
FIG. 3B of the accompanying drawings shows twoweight adjustment portions cavities 316 created inFIG. 3A . Although it may generally be desirable to minimize the weight near a top portion of agolf club head 300 when one desires to lower the CG,top cavity 316 can not be left completely blank in this current embodiment of the present invention, as the entirepre-form billet 301 will eventually be forged into the shape of agolf club head 300, causing anyempty cavity 316 to collapse upon itself. Hence, in this current exemplary embodiment of the present invention, thetop cavity 316 may be filled with a lightweightweight adjustment portion 314, while thelower cavity 316 may be filled with a heavyweightweight adjustment portion 315. The lightweightweight adjustment portion 314 may generally be made out of a third material having a third density, wherein the heavyweightweight adjustment portion 315 may generally be made out of second material having a second density. In one exemplary embodiment of the present invention, the third density may generally be less than about 7.0 g/cc, wherein the second density may generally be greater than about 7.8 g/cc; while the first material used to form thebody portion 302 of thegolf club head 300 may generally have a first density of about 7.8 g/cc. -
FIG. 3C of the accompanying drawings shows the final stage of thepre-form billet 301 that has monolithically encased theweight adjustment portions internal cavities 316 of thepre-form billet 301. More specifically, the creation of the pre-form billet shown inFIG. 3C involves filling in the remaining volume of thecavities 316 with a first material to encase theweight adjustment portions pre-form billet 301. Similar to the above discussion, thepre-form billet 301, is subsequently forged to create agolf club head 300 as shown inFIG. 3D , wherein theweight adjustment portions body portion 302 of thegolf club head 300. - Similar to the methodology described above, the co-forging of the third material within the cavity created within the first material, the third material may generally need to have a third flow stress that is similar with the first flow stress of the first material and a third thermal expansion coefficient less than the first thermal expansion coefficient of the first material. More specifically, in one exemplary embodiment of the present invention, the third material may be a 6-4 Titanium material having a third flow stress of about 10 ksi at a forging temperature of about 1,100° C. and a third thermal expansion coefficient of about 6.1 μin/in ° F.
- Although
FIGS. 2A-2D andFIGS. 3A-3D show different embodiments of the present invention used to achieve a higher MOI and a lower CG respectively, these features are not mutually exclusive from one another. In fact, in a further alternative embodiment of the present invention shown inFIGS. 4A-4D , features may be taken from both embodiments discussed above to create a co-forged golf club head with a higher MOI as well as a lower CG all without departing from the scope and content of the present invention. More specifically, inFIGS. 4A-4D , the steps needed to incorporate a lightweightweight adjustment portion 414 near atop portion 406 of agolf club 400 together with two or more heavyweightweight adjustment portions 415 near a toe portion 412 and aheel portion 410 of thegolf club head 400 to create a golf club with higher MOI and a lower CG. -
FIG. 5A-5D of the accompanying drawings shows a further alternative embodiment of the present invention wherein thebody portion 502 of thegolf club head 500 may be comprised of a monolithically encasedweight adjustment portion 514. In this current exemplary embodiment of the present invention, theweight adjustment portion 514 may be relatively large in size, allowing it to replace a majority of thebody portion 502 of thegolf club head 500 once the forging process is completely. In this current exemplary embodiment of the present invention, the monolithically encasedweight adjustment portion 514 may generally be made out of a third material having a third density that is significantly lower than the first density of the first material used to form thebody portion 502 of thegolf club head 500; allowing weight to be taken out from thebody portion 502 of thegolf club head 500. Because the lightweight third material used to form theweight adjustment portion 514 may generally be relatively soft compare to the first material, it is generally desirable to monolithically encase theweight adjustment portion 514 within the internal body of thegolf club head 500, allowing significant weight savings to be achieved without sacrificing feel. - More specifically
FIG. 5A of the accompanying drawings shows apre-form billet 501 similar to the previous figures. However, in this current exemplary embodiment, thecavity 506 is significantly larger within thepre-form billet 501 itself. Thislarge cavity 506 can then be used inFIG. 5B to be filled with aweight adjustment portion 514 to adjust the weight, density, and overall feel of thegolf club head 500. InFIG. 5C , similar to described above, the remaining volume of the cavity 516 is filled with the original first material before the entirepre-form billet 501 is subjected to the forging process to create agolf club head 500. - It is worth noting here that in this current exemplary embodiment, the
hosel portion 504 of thegolf club head 500 is deliberately made from the conventional first material, as the bending characteristics of the second material used to form theweight adjustment portion 514 may generally not be suitable for the bending requirements of an iron typegolf club head 500. More specifically, the third material used to form theweight adjustment portion 514 could be a lightweight iron-aluminum material having a density of less than about 7.10 g/cc, more preferably less than about 7.05 g/cc, and most preferably less than about 7.00 g/cc, all without departing from the scope and content of the present invention. However, numerous other materials can also be used as the third material used to form theweight adjustment portion 514 without departing from the scope and content of the present invention so long as the third material has a density within the range described above. -
FIG. 6 of the accompanying drawings shows an exploded rear perspective view of agolf club head 600 in accordance with a further alternative embodiment of the present invention utilizing a multi-step co-forging process. This multi-step co-forging process, the details of which will be described subsequently inFIGS. 8-14 , allows for an improvement in the ability to precisely place different weight members within different parts of thegolf club head 600. This improvement in the ability to precisely place weighting members not only opens the door to allow multiple different materials to be forged together that were previously impossible due to their inherent material limitations, but it also allows for more improvements in the performance characteristics of agolf club 600 than previously discussed. - More specifically,
FIG. 6 of the accompanying drawings shows a co-forgedgolf club head 600 created using the multi-step co-forging process. Thegolf club head 600 have heavier densityweight adjustment portions 615 at theheel 610 andtoe 612 portion of thegolf club head 600 corresponding to theirrespective cavities 616. Theweight adjustment portions 615 are then combined withcaps 617 to retain theweight adjustment portions 615 together with the body of thegolf club head 600 during the co-forging process. It should be noted that the current exemplarygolf club head 600 utilizes a multi-step co-forging process to install the heavyweight adjustment portions 615 without the need of post manufacturing finishes such as welding, brazing, swaged, or the like. As previously mentioned, the benefit of utilizing such a co-forged process is the uniformity and consistency of the material, resulting in superior performance and feel. However, in addition to the benefit articulated above, the current embodiment of the present invention allows the heavyweight adjustment portions 615 to be placed at the extremities of thegolf club head 600, further improving the center of gravity location as well as the moment of inertia of thegolf club head 600. -
FIG. 7 of the accompanying drawings shows an exploded frontal perspective view of agolf club head 700 in accordance with a further alternative embodiment of the present invention. More specifically,golf club head 700 incorporates a lightweightweight adjustment portion 714 behind astriking face 718 portion of thegolf club head 700 within acavity 716 in a multi-step co-forging process. In this current exemplary embodiment of the present invention, due to the precision co-forging process discussed above, the location and placement of the lightweightweight adjustment portion 714 can be more precisely placed, hence creating the opportunity to reduce weight from thestriking face 718 portion of thegolf club head 700. In order to understand the current multi-step co-forging process,FIGS. 8-14 have been presented below, detailing the steps involved in this multi-step co-forging process. -
FIG. 8 of the accompanying drawings, similar toFIGS. 2-5 above, show apre-form billet 801 used to create a forged golf club head. This forgedbillet 801, is then bent to an L-shape as shown inFIG. 9 to prepare thebillet 901 for the die that begins the forging process.FIGS. 10 a and 10 b shows the frontal and rear view of agolf club head 1000 that's been subjected to the first step of the multi-step co-forging process. In this preliminary step, the billet has been forged to a shape that roughly resembles that of agolf club head 1000. In fact, even in this early stage, the shape of thegolf club 1000 can be seen, as it already has ahosel portion 1004, aheel portion 1010, and atoe portion 1012. In the rear view of thegolf club head 1000 shown inFIG. 10 a, preliminary imprints of thecavity 1016 can already be seen in theheel 1010 andtoe 1012 portion of the golf club head; while in the frontal view of thegolf club head 1000 shown inFIG. 10 b, thecavity 1016 can already be seen near the striking face. - Subsequent to the initial forging step, the
excess trim 1030 may be removed from thegolf club head 1000 and subsequent to that, subjected to another rough forging step. During the forging process, the excess material may flow outside of the confines of the die, resulting in what is commonly known as “flash”. This flash material, as previously discussed, may be trimmed off in between the individual multi-forging steps to improve the adherence to the die in subsequent steps. - The results of this secondary forging step can be shown in
FIGS. 11 a and 11 b. As it can be seen fromFIGS. 11 a and 11 b, thegolf club head 1100 in this current state, is starting to take on a shape that more closely resembles that of a finished product. In addition to the overall shape being more defined, the boundaries and shapes of thecavities 1116 are also starting to take on their respective shape as well. Subsequent to this secondary forging step, the weight adjustment portions can be added into thespecific cavities 1116 before thegolf club head 1100 is subjected to the final forging step. - The relationship between the weight adjustment portions to the
cavities 1116 on thegolf club head 1100 can be shown more clearly inFIGS. 12 a and 12 b. Here, inFIGS. 12 a and 12 b, it can be seen that thecavity 1216 on the rear portion of thegolf club head 1200 may be filled withweight adjustment portions 1215 that may generally have a higher density than the body of thegolf club head 1200. The high densityweight adjustment portions 1215 may then be covered up with acap 1217 made out of a similar material as the body of thegolf club head 1200, allowing high densityweight adjustment portions 1215 to be retained within thecavity 1216. In the front of thegolf club head 1200, thecavity 1216 may be filled with aweight adjustment member 1214 having a lower density than the body portion of thegolf club head 1200. Similar to the rear, thisweight adjustment portion 1214 may be secured in thecavity 1216 with a cap like mechanism that also serves as astriking face 1218. Thestriking face 1218, similar to thecap 1217, may be made out of a similar material as the body of thegolf club head 1200. Having thecap 1217 and thestriking face 1218 be made out of the same material as the remainder of the body of thegolf club head 1200 is beneficial because it allows these two components to be welded to the body portion of thegolf club head 1200. Having these components welded in place allows theweight adjustment portions 1215 to be secured within their ownrespective cavities 1216 before the final forging step that completes the current multi-step co-forging process. - In an alternative embodiment of the present invention, the
cap 1217 may not even be necessarily needed to completely cover up thecavity 1216 and theweight adjustment member 1214. In fact, in an alternative embodiment of the present invention, thecap 1217 only needs to partially cover theweight adjustment portion 1215 to a degree that sufficiently prevents theweight adjustment portion 1215 from separating from the body of thegolf club head 1200. - The final forging process involved in this process is generally creates a
golf club head 1200 that can be considered “co-forged”, as now thegolf club head 1200 contains two or more different materials being forged together in this final step.FIGS. 13 a and 13 b show the results of thegolf club head 1300 after it has completed the final co-forging step. In its current state, thegolf club head 1300 has taken its final shape, and theweight adjustment members caps 1317 andstriking face plate 1318. Although thegolf club head 1300 may have taken their form, there are stillexcessive flash 1330 around the perimeter of thegolf club head 1300 that needs to be trimmed before thegolf club head 1300 takes its final form. -
FIGS. 14 a and 14 b show the completedgolf club head 1400 as a result of this co-forging process. As it can be seen here inFIGS. 14 a and 14 b, theexcess flash 1330 has already been trimmed, improving the aesthetic appeal of thegolf club head 1400. As previously mentioned, as a result of this co-forging process, theweight adjustment portions 1416 and 1418 are seamlessly and monolithically encased with the body of thegolf club head 1400 via thecap 1417 and thestriking face plate 1318. As previously discussed, the advantage of having theweight adjustment portions 1416 seamlessly and monolithically encased with the body of thegolf club head 1400 via this co-forged process is that it prevents rattling, and improves the solid feel of thegolf club head 1400. In fact, utilizing this process, the present golf club head can achieve a feel that is almost non-discernible from a unitary forged golf club head utilizing conventional forging methodologies. - Alternatively speaking, it can also be said that this present multi-step co-forging methodology creates a unique relationship between the
weight adjustment portions 1416 and 1418 and the cavity 1216 (seeFIG. 12 ) that it sits in. More specifically, it can be said that the outer surface area of theweight adjustment portion 1416 may generally be identical to the inner surface area of thecavity 1216. Thecavity 1216 may generally include the surface area of anycaps 1217 orface plate 1218 used to complete thecavity 1216 created by the rough forging steps. (SeeFIG. 12 ) Although the symmetry in shape and surface area between thecavity 1216 and theweight adjustment portion 1416 may not appear like an innovative achievement initially, the reality of the situation is that unless a co-forged step is involved, such a seamless interface between the two components are impossible to achieve. Given the bonding constraints of the materials used for different parts of the golf club head, the current innovative co-forging method is the only way to achieve such a seamless interface between these components. - In addition to above, the current multi-step co-forging process may differ from the pure co-forging process in that it no longer requires the two materials to have similar flow stresses between the different materials. This elimination of the requirement that the material needs to have similar flow stresses may be beneficial because it allows a wider range of materials to be used, especially when it comes to exotic materials providing extreme weighting benefits such as Tungsten. The current multi-step co-forging process is capable of achieving this by forging the cavity for the weight before using a final cap type material to fill the gap around the cavity to completely enclose the weight adjustment portion within the cap type material. Despite the elimination of the need for the materials to have similar flow stress, the need for the second material to have a smaller thermal expansion coefficient as the first material still stands true in this multi-step co-forging process. This requirement still stands because the second material, although encompassed in a cavity via a cap, is still subjected to the same forging temperature as the external first material. Any excessive expansion of the second material would degrade the structural rigidity of the cap, causing potential failures in the bonding process.
- Other than in the operating example, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, moment of inertias, center of gravity locations, loft, draft angles, various performance ratios, and others in the aforementioned portions of the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear in the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the preceding specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
- Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting form the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.
- It should be understood, of course, that the foregoing relates to exemplary embodiments of the present invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
Claims (20)
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US13/927,764 US20130288823A1 (en) | 2011-11-28 | 2013-06-26 | Co-forged golf club head and method of manufacture |
US14/078,380 US9387370B2 (en) | 2011-11-28 | 2013-11-12 | Co-forged golf club head and method of manufacture |
CN201310730900.7A CN104248833B (en) | 2013-06-26 | 2013-12-26 | Co-forged golf club head and method of manufacture |
JP2014004729A JP2015009142A (en) | 2013-06-26 | 2014-01-15 | Co-forged golf club head and method of manufacturing the same |
US14/580,894 US9616303B2 (en) | 2011-11-28 | 2014-12-23 | Co-forged golf club head and method of manufacture |
US15/065,104 US20160184669A1 (en) | 2011-11-28 | 2016-03-09 | Co-forged golf club head and method of manufacture |
US15/182,275 US20160287955A1 (en) | 2011-11-28 | 2016-06-14 | Golf club head and method of manufacture |
US15/188,726 US10398951B2 (en) | 2011-11-28 | 2016-06-21 | Co-forged golf club head and method of manufacture |
US15/332,864 US10391370B2 (en) | 2011-11-28 | 2016-10-24 | Co-forged golf club head and method of manufacture |
US15/379,784 US10220275B2 (en) | 2011-11-28 | 2016-12-15 | Co-forged golf club head and method of manufacture |
US15/455,781 US10071292B2 (en) | 2011-11-28 | 2017-03-10 | Co-forged golf club head and method of manufacture |
US15/713,374 US20180036605A1 (en) | 2011-11-28 | 2017-09-22 | Set of golf club heads and method of manufacture |
US16/000,021 US20180280768A1 (en) | 2011-11-28 | 2018-06-05 | Golf club head and method of manufacture |
US16/228,141 US20190118049A1 (en) | 2011-11-28 | 2018-12-20 | Co-forged golf club head and method of manufacture |
US16/255,576 US10888917B2 (en) | 2011-11-28 | 2019-01-23 | Co-forged golf club head and method of manufacture |
US16/406,382 US11065513B2 (en) | 2011-11-28 | 2019-05-08 | Set of golf club heads and method of manufacture |
US17/338,435 US20210291025A1 (en) | 2011-11-28 | 2021-06-03 | Co-forged golf club head and method of manufacture |
US17/351,702 US11504589B2 (en) | 2011-11-28 | 2021-06-18 | Set of golf club heads and method of manufacture |
US17/688,326 US11918867B2 (en) | 2011-11-28 | 2022-03-07 | Co-forged golf club head and method of manufacture |
US17/882,354 US20220370868A1 (en) | 2011-11-28 | 2022-08-05 | Co-forged golf club head and method of manufacture |
US17/981,883 US20230057513A1 (en) | 2011-11-28 | 2022-11-07 | Set of golf club heads and method of manufacture |
US18/483,220 US20240033590A1 (en) | 2011-11-28 | 2023-10-09 | Set of golf club heads and method of manufacture |
US18/487,711 US20240042289A1 (en) | 2011-11-28 | 2023-10-16 | Co-forged golf club head and method of manufacture |
US18/422,874 US20240157205A1 (en) | 2011-11-28 | 2024-01-25 | Co-forged golf club head and method of manufacture |
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US13/305,087 US8926451B2 (en) | 2011-11-28 | 2011-11-28 | Co-forged golf club head and method of manufacture |
US13/927,764 US20130288823A1 (en) | 2011-11-28 | 2013-06-26 | Co-forged golf club head and method of manufacture |
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US13/305,087 Continuation-In-Part US8926451B2 (en) | 2011-11-28 | 2011-11-28 | Co-forged golf club head and method of manufacture |
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US14/078,380 Continuation-In-Part US9387370B2 (en) | 2011-11-28 | 2013-11-12 | Co-forged golf club head and method of manufacture |
US15/379,784 Continuation US10220275B2 (en) | 2011-11-28 | 2016-12-15 | Co-forged golf club head and method of manufacture |
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US15/379,784 Active 2032-08-26 US10220275B2 (en) | 2011-11-28 | 2016-12-15 | Co-forged golf club head and method of manufacture |
US16/255,576 Active 2032-05-30 US10888917B2 (en) | 2011-11-28 | 2019-01-23 | Co-forged golf club head and method of manufacture |
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US15/379,784 Active 2032-08-26 US10220275B2 (en) | 2011-11-28 | 2016-12-15 | Co-forged golf club head and method of manufacture |
US16/255,576 Active 2032-05-30 US10888917B2 (en) | 2011-11-28 | 2019-01-23 | Co-forged golf club head and method of manufacture |
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Also Published As
Publication number | Publication date |
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US20190151728A1 (en) | 2019-05-23 |
US20170095709A1 (en) | 2017-04-06 |
US10220275B2 (en) | 2019-03-05 |
US10888917B2 (en) | 2021-01-12 |
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