Golf Club Head With High-Density Heel And Toe Weight And Method Of Making Same

Abstract

A method of forming a golf club head includes providing a body having an end portion (e.g., a heel end or a toe end of the club head) wherein the body end portion includes a lower surface and a boss extending therefrom. The method comprises providing a weight having a top surface and a cavity configured to receive the boss, and inserting the boss on the body into the cavity in the weight by rotating the weight such that the boss interlocks with the cavity and so that at least a portion of the top surface of the weight contacts at least a portion of the lower surface of the body end portion. The weight further includes a protrusion having a concave surface and the body has a corresponding convex surface. The weight is rotated about an axis extending through the body such that the concave surface of the weight bears on the convex surface of the body.

1 . A method of forming a golf club head, the method comprising: 
 providing a body comprising a front surface, a rear surface, a body surface between the front and rear surfaces, and a first end portion between the front and rear surfaces, wherein the first end portion comprises a lower surface and a boss extending therefrom;    providing a weight extending from the front surface of the body to the rear surface of the body, the weight comprising a top surface, a cavity to receive the boss, and a protrusion comprising a weight surface; and    interlocking the boss and the cavity so that at least a portion of the top surface of the weight is proximate to at least a portion of the lower surface of the first end portion and so that the weight surface induces a force upon the body surface when the golf club head is at an address position.    
   
   
       2 . The method of  claim 1 , further comprising securing the weight to the first end portion.  
   
   
       3 . The method of  claim 2 , 
 wherein: 
 securing the weight to the first end portion comprises fastening the weight to the body using a screw inserted through the weight into the boss.  
   
   
   
       4 . The method of  claim 1 , wherein the first end portion of the body corresponds to a heel end of the body.  
   
   
       5 . The method of  claim 1 , wherein the first end portion of the body corresponds to a toe end of the body.  
   
   
       6 . The method of  claim 1 , 
 wherein: 
 the body comprises a second end portion; and  
 the method further comprises providing a second weight to interlock with the second end portion of the body.  
   
   
   
       7 . The method of  claim 1 , 
 wherein: 
 the weight comprises a front surface; and  
 interlocking the boss and the cavity comprises positioning the weight such that the front surface of the weight is substantially flush with the front surface of the body thereby forming a striking face of the golf club head at the front surface of the body.  
   
   
   
       8 . The method of  claim 1 , 
 wherein: 
 the body further comprises a sole;  
 the weight further comprises a bottom surface; and  
 interlocking the boss and the cavity comprises positioning the weight such that the bottom surface of the weight is substantially flush with the sole.  
   
   
   
       9 . The method of  claim 1 , wherein interlocking the boss and the cavity further comprises: 
 rotating the weight about an axis normal to the front surface of the body so that at least the portion of the top surface of the weight is proximate to at least the portion of the lower surface of the first end portion and so that the weight surface induces the force upon the body surface when the golf club head is at the address position.    
   
   
       10 . The method of  claim 1 , further comprising: 
 providing a second weight;    removing the weight from the body; and    interlocking the body and the second weight.    
   
   
       11 . The method of  claim 10  wherein: 
 providing the second weight extending from the front surface of the body to the rear surface of the body, the second weight comprising a second weight top surface, a second weight cavity to receive the boss, and a second weight protrusion comprising a second weight surface; and    interlocking the boss and the second weight cavity so that at least a portion of the second weight top surface is proximate to at least the portion of the lower surface of the first end portion and so that the second weight surface induces a force upon the body surface when the golf club head is at the address position.    
   
   
       12 . The method of  claim 1 , wherein the body surface comprises a convex shape and the weight surface comprises a concave shape to mate with the convex shape of the body surface.  
   
   
       13 . A club head comprising: 
 a body comprising a front surface, a rear surface, a body surface between the front and rear surfaces, and a first end portion between the front and rear surfaces, wherein the first end portion comprises a lower surface and a boss extending therefrom; and    a weight extending from the front surface of the body to the rear surface of the body, the weight comprising a top surface, a cavity to receive the boss, and a protrusion comprising a weight surface;    wherein:    the boss and the cavity interlock so that at least a portion of the top surface of the weight is proximate to at least a portion of the lower surface of the first end portion and so that the weight surface induces a force upon the body surface when the golf club head is at an address position.    
   
   
       14 . The club head of  claim 13 , wherein the weight is secured to the first end portion.  
   
   
       15 . The club head of  claim 14 , 
 wherein: 
 the weight secured to the first end portion comprises the weight fastened to the body using a screw inserted through the weight into the boss.  
   
   
   
       16 . The club head of  claim 13 , wherein the first end portion of the body corresponds to a heel end of the body.  
   
   
       17 . The club head of  claim 13 , wherein the first end portion of the body corresponds to a toe end of the body.  
   
   
       18 . The club head of  claim 13 , 
 wherein: 
 the body further comprises a second end portion; and  
 the club head further comprises a second weight that interlocks with the second end portion of the body.  
   
   
   
       19 . The club head of  claim 13 , 
 wherein: 
 the weight further comprises a front surface; and  
 wherein when the boss and the cavity are interlocked, a front surface of the weight is substantially flush with the front surface of the body thereby forming a striking face of the golf club head at the front surface of the body.  
   
   
   
       20 . The club head of  claim 13 , 
 wherein: 
 the body further comprises a sole;  
 the weight further comprises a bottom surface; and  
 when the boss and the cavity are interlocked, a bottom surface of the weight is substantially flush with the sole.  
   
   
   
       21 . The club head of  claim 13 , further comprising: 
 a second weight having a different density than the weight;    wherein:    the body interlocks with the second weight.    
   
   
       22 . The club head of  claim 21  wherein: 
 the second weight extends from the front surface of the body to the rear surface of the body, the second weight comprising a second weight top surface, a second weight cavity to receive the boss, and a second weight protrusion comprising a second weight surface; and    the boss and the second weight cavity interlock so that at least a portion of the second weight top surface is proximate to at least the portion of the lower surface of the first end portion so that the second weight surface induces a force upon the body surface when the golf club head is at the address position.    
   
   
       23 . The club head of  claim 13 , wherein the body surface comprises a convex shape and the weight surface comprises a concave shape to mate with the convex shape of the body surface.  
   
   
       24 . The club head of  claim 13 , wherein the body comprises a material comprising a density less than a density of the weight.  
   
   
       25 . The club head of  claim 24 , wherein the body comprises titanium and the weight comprises tungsten.  
   
   
       26 . The club head of  claim 13 , wherein the club head is a putter head.  
   
   
       27 . The club head of  claim 13 , wherein: 
 the first end portion of the body corresponds to a heel end of the body;    the body further comprises a second end portion between the front and rear surfaces and corresponding to a toe end of the body; and    the club head further comprises a second weight located at the toe end of the body at the front surface and the rear surface.    
   
   
       28 . The club head of  claim 27 , wherein the weight and the second weight are absent from a portion of the body between the heel end and the toe end.  
   
   
       29 . The club head of  claim 28 , wherein the weight and the second weight extend from the front surface of the body to the rear surface of the body.  
   
   
       30 . The club head of  claim 13 , wherein the weight and a second weight extend from the front surface to the rear surface.  
   
   
       31 . The club head of  claim 13 , wherein: 
 the body further comprises a top surface; and    the weight forms a portion of the top surface.    
   
   
       32 . The club head of  claim 13 , wherein the boss is integral with the body.  
   
   
       33 . The club head of  claim 13 , wherein: 
 the cavity comprises a shape; and    the boss comprises a shape complementary to the shape of the cavity.    
   
   
       34 . A golf club comprising: 
 a body comprising a front surface, a rear surface, a body surface between the front and rear surfaces, and a first end portion between the front and rear surfaces, wherein the first end portion comprises a lower surface and a boss extending therefrom;    a weight extending from the front surface of the body to the rear surface of the body, the weight comprising a top surface, a cavity to receive the boss, and a protrusion comprising a weight surface; and    a golf club shaft coupled to the body;    wherein:    the boss and the cavity interlock so that at least a portion of the top surface of the weight is proximate to at least a portion of the lower surface of the first end portion and so that the weight surface induces a force upon the body surface when the golf club head is at an address position.    
   
   
       35 . The golf club of  claim 34  wherein: 
 the body surface comprises a convex shape and the weight surface comprises a concave shape to mate with the convex shape of the body surface;    the end portion of the body corresponds to a heel end of the body;    the body further comprises a second end portion extending between the front and rear surfaces of the body, and corresponding to a toe end of the body;    the golf club further comprises a second weight that interlocks with the second end portion of the body; and    the body comprises a material comprising a density less than that of the weight and the second weight.