US 11,745,063 B2
Forged iron head
Yujen Huang, Pingtung (TW); Erik M. Henrikson, Phoenix, AZ (US); and Matthew W. Simone, Phoenix, AZ (US)
Assigned to Karsten Manufacturing Corporation, Phoenix, AZ (US)
Filed by Karsten Manufacturing Corporation, Phoenix, AZ (US)
Filed on Feb. 22, 2022, as Appl. No. 17/652,063.
Application 17/652,063 is a continuation of application No. 16/858,520, filed on Apr. 24, 2020, granted, now 11,253,758.
Claims priority of provisional application 62/839,411, filed on Apr. 26, 2019.
Prior Publication US 2022/0176210 A1, Jun. 9, 2022
Int. Cl. A63B 53/04 (2015.01); A63B 53/08 (2015.01)
CPC A63B 53/047 (2013.01) [A63B 53/08 (2013.01); A63B 53/0412 (2020.08); A63B 2053/0491 (2013.01); A63B 2209/10 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A method for forming an iron-type golf club head comprising:
providing a main club body, a lightweight insert, a cap, and a weight;
wherein the main club body comprises:
a front, a rear, a toe end, a heel end, a strikeface, a strikeface front surface configured to impact a golf ball, a hosel configured to receive a golf shaft, a top-rail, a sole, a strikeface rear surface, and a perimeter sidewall formed by the top rail, the sole, the toe end and the heel end;
wherein the perimeter sidewall extends rearwardly generally perpendicular to the strikeface;
wherein a back cavity is defined by the perimeter sidewall and the strikeface rear surface; and
wherein the back cavity is open toward the rear of the main club body;
wherein the perimeter sidewall further comprises a locking groove recessed into the perimeter sidewall at least partially surrounding the strikeface rear surface;
wherein the locking groove is recessed into the perimeter sidewall in a direction parallel to the strikeface rear surface offset rearwardly from the strikeface rear surface;
wherein the main club body comprises an aperture in the heel end such that the aperture is a hole open to a heel end outer surface and also open to the back cavity;
wherein the main club body further comprises a first material having a first density;
wherein the first material comprises a first metallic alloy;
providing a forging die comprising an upper die platen and a lower die platen;
placing the main body within the forging die lower platen with the strikeface front surface oriented downwards and the back cavity is oriented upwards;
aligning a billet comprising a second material within the back cavity;
the second material having a second density lower than the first density;
inserting a pull rod through the aperture into the back cavity under the billet;
pressing the upper forging die platen down upon the lower forging die forming the lightweight insert;
lifting the upper forging die platen, and withdrawing the pull rod through the aperture forming a void within the lightweight insert;
receiving a weight within the void through the aperture;
sealing the aperture with the cap.