U.S. patent number RE40,273 [Application Number 11/078,917] was granted by the patent office on 2008-04-29 for method of manufacturing an archery broadhead with sintered components.
This patent grant is currently assigned to G5 Outdoors, L.L.C.. Invention is credited to Louis Grace, Jr., Nathaniel E. Grace.
United States Patent |
RE40,273 |
Grace, Jr. , et al. |
April 29, 2008 |
Method of manufacturing an archery broadhead with sintered
components
Abstract
The present invention relates generally to a method of
manufacturing broadhead components utilizing a powder injection
molding (PIM) process that reduces the number of operations, thus
simplifying the manufacturing process required to produce a
finished product while maintaining the precision essential to the
function of this commodity. The method of manufacturing includes
powder injection molding one or more than one components for a
broadhead, sintering the component(s) at an elevated temperature to
form component(s) and assembling the component(s) to form a
broadhead.
Inventors: |
Grace, Jr.; Louis (North
Street, MI), Grace; Nathaniel E. (Port Huron, MI) |
Assignee: |
G5 Outdoors, L.L.C. (Memphis,
MI)
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Family
ID: |
39321824 |
Appl.
No.: |
11/078,917 |
Filed: |
March 14, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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09910385 |
Jul 20, 2001 |
6595881 |
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09546146 |
Apr 10, 2000 |
6290903 |
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60219474 |
Jul 20, 2000 |
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Reissue of: |
10360690 |
Feb 7, 2003 |
06749801 |
Jun 15, 2004 |
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Current U.S.
Class: |
419/36; 419/38;
473/583; 473/584 |
Current CPC
Class: |
F42B
6/08 (20130101) |
Current International
Class: |
B22F
3/10 (20060101) |
Field of
Search: |
;419/36,38
;473/583,584 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"An Introduction to Injection Molding Metals & Ceramics", Jun.
1999, pp. 4-5. cited by examiner .
"Bowhunting Equipment", 1999 Buyers Guide, p. 70. cited by examiner
.
Web site Cabela's--http://www.cabelas.com, "BoneBuster Broadheads".
cited by examiner.
|
Primary Examiner: Wyszomierski; George
Attorney, Agent or Firm: Warner Norcross & Judd LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of prior application Ser. No.
09/910,385 entitled "Broadhead and Method of Manufacture" filed on
Jul. 20, 2001 now U.S. Pat. No. 6,595,881, which is a continuation
in part of prior application Ser. No. 09/546,146 entitled
"Broadhead and Method of Manufacture" filed on Apr. 10, 2000 now
U.S. Pat. No. 6,290,903 and which also claims priority under 35
U.S.C. .sctn.119(e) to U.S. Provisional Patent Application No.
60/219,474 filed on Jul. 20, 2000 and entitled Expanding Archery
Broadhead, the specification and drawings of which are hereby
expressly incorporated by reference.
Claims
What is claimed is:
1. A method of manufacturing an archery broadhead comprising:
powder injection molding .[.at least one broadhead component
selected from the group consisting of a ferrule and a blade.].
.Iadd., with a powdered metal composition, a ferrule including a
body and defining a slot.Iaddend.; sintering said .[.at least one
broadhead component.]. .Iadd.ferrule .Iaddend.at an elevated
temperature to form a sintered .[.broadhead component.].
.Iadd.ferrule, the slot being formed and bounded substantially by
metal.Iaddend.; and connecting .[.said.]. .Iadd.a .Iaddend.blade to
said ferrule.
2. The method of manufacturing an archery broadhead of claim 1
wherein said blade is releasably secured to said ferrule with a
retainer.
3. .[.The.]. .Iadd.A .Iaddend.method of manufacturing an archery
broadhead .[.of claim 1.]. .Iadd.comprising: powder injection
molding at least one broadhead component selected from the group
consisting of a ferrule and a blade; sintering said at least one
broadhead component at an elevated temperature to form a sintered
broadhead component; and connecting said blade to said
ferrule,.Iaddend. wherein said blade is pivotally coupled to said
ferrule .[.with a retainer.]. .Iadd.so that the blade is expandable
from a retracted position to a deployed position.Iaddend..
4. The method of manufacturing an archery broadhead of claim 1
.[.further.]. comprising: forming a greenware ferrule from a
powdered composition; sintering said greenware ferrule at an
elevated temperature to form a sintered ferrule; and connecting
said blade to said sintered ferrule with .[.said.]. .Iadd.a
.Iaddend.retainer.
5. The method of manufacturing an archery broadhead of claim 4
wherein forming a greenware ferrule comprises forming said ferrule
having a shank portion extending from an end thereof.
6. The method of manufacturing an archery broadhead of claim 4
wherein forming a greenware ferrule comprises forming said ferrule
having a tip portion extending from an end thereof.
7. .[.The.]. .Iadd.A .Iaddend.method of manufacturing an archery
broadhead .[.of claim 4.]. .Iadd.comprising: powder injection
molding at least one broadhead component selected from the group
consisting of a ferrule and a blade; forming a greenware ferrule
from a powdered composition; sintering said greenware ferrule at an
elevated temperature to form a sintered ferrule; and connecting
said blade to said sintered ferrule,.Iaddend. wherein forming a
greenware ferrule comprises forming a ferrule having a boss formed
thereon, said boss being received in an aperture formed in said
blade to pivotally couple said blade to said ferrule.
8. The method of manufacturing an archery broadhead of claim 4
wherein forming a greenware ferrule comprises forming a ferrule
having a slot formed therein and said blade is received within said
slot to releasably secure said blade to said ferrule.
9. The method of manufacturing an archery broadhead of claim 1
further comprising: forming a greenware blade from a powdered
composition; sintering said greenware blade at an elevated
temperature to form a sintered blade; and connecting said sintered
blade to said ferrule with .[.said.]. .Iadd.a
.Iaddend.retainer.
10. The method of manufacturing an archery broadhead of claim 9
wherein said ferrule is provided with a longitudinal slot and said
blade is received within said slot to releasably secure said blade
to said ferrule.
11. .[.The.]. .Iadd.A .Iaddend.method of manufacturing an archery
broadhead .[.of claim 10.]. .Iadd.comprising: powder injection
molding at least one broadhead component selected from the group
consisting of a ferrule and a blade; forming a greenware blade from
a powdered composition; sintering said greenware blade at an
elevated temperature to form a sintered blade; and connecting said
sintered blade to said ferrule, wherein said ferrule is provided
with a longitudinal slot and said blade is received within said
slot to releasably secure said blade to said ferrule,.Iaddend.
wherein forming a greenware blade comprises forming said greenware
blade having a bead along an edge thereof, said bead received
within said slot when said sintered blade is releasably secured to
said ferrule.
12. The method of manufacturing an archery broadhead of claim 8
further comprising: forming a plurality of greenware blade from
said powdered composition; sintering said plurality of greenware
blades at an elevated temperature to form a plurality of sintered
blades; and connecting said plurality of sintered blades to said
ferrule with .[.said.]. .Iadd.a .Iaddend.retainer.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to an archery arrow and
more specifically to the design and method of manufacture of the
broadhead for an archery arrow.
The components of a typical archery broadhead include a ferrule or
body having one or more blades extending therefrom. Additionally,
the tip of the broadhead may be a separate component secured to the
front of the ferrule. Two types of archery broadheads are generally
known in the industry as fixed or replaceable blade broadheads and
moveable or mechanical blade broadheads. The moveable blade
broadheads, by design, are in a closed position in flight and open
upon impact with the target.
Conventionally, the components of archery broadheads are
manufactured using a variety of processes. The ferrule is
conventionally turned or stamped with a male thread at the end
where it attaches to an arrow shaft. Where the tip is not formed
.[.is.]. .Iadd.as .Iaddend.an integral of the ferrule, an internal
or female thread is formed on the front of the ferrule for
receiving and securing the broadhead tip. Additional machining
operations are necessary to provide the slots or other openings in
the ferrule essential to the attachment of the blades. The blades
are generally stamped steel with a uniform cross-section that
requires subsequent grinding and honing operations to provide the
sharpened edges. Thus, removable blades .[.adds.]. .Iadd.add
.Iaddend.to the complexity of .[.manufacturer.].
.Iadd.manufacturing.Iaddend., as does the use of irregular skin
surface treatments on the ferrule. Tapered blades instead of
stamped blades add strength and resistance to bending.
Broadhead components manufactured using conventional processes
require a variety of costly equipment to achieve and maintain the
precision essential to proper functioning of this commodity.
Accordingly, there is a need to provide an efficient method of
manufacturing .[.from.]. .Iadd.of .Iaddend.many of the broadhead
components to reduce the cost, add design flexibility and still
maintain the precision required.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of
manufacturing broadhead components utilizing a process that reduces
the number of operations, and thus simplifies the process.[.,.].
required to produce a finished product while maintaining the
precision essential to the function of this commodity.
It is an additional object of the present invention to provide
different materials as dictated by the particular application, in
the manufacture of broadhead components utilizing the
aforementioned process.
It is another object of the present invention to provide a
monolithic ferrule, manufactured utilizing a powder injection
molding (PIM) process incorporating integral design features
necessary for the proper assembly and functioning of the
broadhead.
It is a further object of the present invention to provide
broadhead blades, manufactured by the PIM process, with tapered or
otherwise varying cross sections so as to enhance the strength
.[.in.]. .Iadd.and .Iaddend.aerodynamic qualities of the
broadhead.
It is yet another object of the present invention to provide
blades, manufactured by the PIM process, having scalloped, serrated
or otherwise varying cutting edge treatments so as to enhance the
cutting and penetration abilities of the broadhead.
It is an additional object of the present invention to provide a
broadhead point, manufactured by the PIM process which may be used
interchangeably with a variety of ferrules.
It is still another object of the present invention to provide a
ferrule and broadhead point, either separately or integral with the
ferrule, manufactured by the PIM process having a surface texture
so as to enhance the aerodynamic and penetration qualities of the
broadhead.
In accordance with a first preferred embodiment of the present
invention, an expanding-blade broadhead is provided including a
ferrule having an integral boss formed thereon, a plurality of
cutting blades supported on the boss and pivotally coupled to the
ferrule and a collar for retaining the blades on the boss while
permitting free rotation thereof. A threaded shank portion is
formed on the end of the ferrule opposite the point for securing
the broadhead to the arrow shaft in a conventional manner. The use
of powdered metallurgy and subsequent sintering processes provides
a preferred, but not essential method of manufacturing the ferrule
and retaining collar.
In accordance with a second preferred embodiment of the present
invention, a fixed blade broadhead is provided including a ferrule
having a blade receiving slot formed therein, a broadhead tip
threadedly secured to the ferrule and a plurality of cutting blades
disposed in the slots formed in the ferrule and releasably secured
thereto by the broadhead tip. A threaded shank portion is formed on
the end of the ferrule opposite the point for securing the
broadhead to an arrow shaft in a conventional manner. The use of
powdered metallurgy and subsequent sintering processes provides a
preferred, but not essential method of manufacturing the ferrule,
blades and broadhead tip.
These and other objects, features and advantages of the present
invention will become apparent from the following description when
viewed in accordance with the accompanying drawings and appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an expanding-blade broadhead in
accordance with the present invention in which the blades are in a
retracted position and with an arrow shaft illustrated in phantom
lines;
FIG. 2 is a cross-section taken through lines II--II shown in FIG.
1;
FIG. 3 is a detailed perspective view illustrating the ferrule and
retaining collar of the present invention;
FIG. 4 is a cross-sectional view of a portion of the ferrule and
the retaining collar shown in FIG. 3;
FIG. 5 is an exploded side view illustrating the components of the
expanding-blade broadhead of the present invention;
FIG. 6 is a partial cross-section illustrating the pivotal
connections between the ferrule and the cutting blade;
FIG. 7 is a side view of the expanding-blade broadhead shown in a
retracted position;
FIG. 8 is a side view of the expanding-blade broadhead shown in the
deployed position;
FIG. 9 is an exploded side view of a fixed-blade broadhead in
accordance with the present invention with an arrow shaft
illustrated in phantom lines;
FIG. 10 is a cross-sectional view taken through the ferrule portion
of the broadhead illustrated in FIG. 9;
FIG. 11 is an alternate embodiment of a ferrule for the fixed-blade
broadhead having a surface texture treatment;
FIG. 12 is a cross-sectional view taken through the ferrule portion
of the broadhead illustrated in FIG. 11;
FIG. 13 is a detailed cross-section view taken through the blade
portion of the broadhead illustrated in FIG. 9 showing tapered
blade possibilities;
FIG. 14 is an alternate embodiment of the blade for the fixed blade
broadhead assembly illustrated in FIG. 9;
FIG. 15 is a schematic diagram generally illustrating the method of
manufacturing components of the broadhead in accordance with the
present invention using powdered metallurgy technology; and
FIG. 16 is a flow chart illustrating the method of manufacturing
the components of the broadhead in accordance with the present
invention using powdered metallurgy technology.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the FIGS. 1-8, a first preferred embodiment
of the present invention is illustrated in the form of an
expandable-blade broadhead. Broadhead 10 includes ferrule 12,
cutting blades 14 pivotally coupled to ferrule 12 and collar 16
disposed over an end of ferrule 12 for retaining cutting blades 14
thereon.
A substantially conical or trocar shaped tip 18 is formed at a
forward end of ferrule 12. The body 20 of ferrule 12 is generally
conical or trocar shaped having a triangular cross-section as best
seen in FIG. 2. Each of the vertices 22 of body 20 has a slot 24
formed therein which receives cutting blade 14 when in the
retracted position. Ferrule 12 further has a base portion 26 having
three lugs 28 extending radially from the ferrule. A boss 30
extends from the radial face 32 of lug 28. Shank 34 extends
rearwardly from base portion 26 and has a male threaded portion
.Iadd.36 .Iaddend.formed at the end thereof for operably coupling
broadhead 12 to arrow shaft 38.
Cutting blades 14 have a cutting edge 40 formed thereon. Aperture
42 is formed in a bottom portion of cutting blade 14 and is adapted
to .[.received.]. .Iadd.receive .Iaddend.boss 30 for pivotally
coupling cutting blade 14 to ferrule 12. Collar 16 is slidably
received over shank 34 and has an annular skirt portion 44 with
fingers 46 extending longitudinally forward such that fingers 46
are positioned adjacent to lugs 28 formed on ferrule 12. A radial
face 48 defined by fingers 46 is generally parallel to but spaced
apart from radial face 32 to further define slot 24. As best seen
in FIG. 6 a slight clearance is provided between the end of boss 30
and the radial face 48 of finger 46 such that collar 16 may be
readily positioned onto ferrule 12, while at the same time
sufficiently retaining cutting blade 14 onto boss 30.
As best seen in FIG. 5, broadhead 10 is threadedly secured to arrow
shaft 38 such that the forward face 50 of arrow shaft 38 pushes
retaining collar 16 onto ferrule 12. As presently preferred, a
compliant element 52 is interdisposed between rearward face 54
formed on retaining collar 16 and forward face 50 of arrow shaft 38
to prevent loosening therebetween.
While various design features have been described above, one
skilled in the art will readily recognize that certain
modifications, variations and changes may be made without departing
from the scope of the invention. In this regard the overall shape
and geometric configuration of the ferrule may be adapted to
various shapes. In addition, the expanding broadhead may
incorporate more or less cutting blades as the particular
application requires. The retaining collar may be secured to the
ferrule by other suitable manners. The shaft of the ferrule may be
formed of a separate piece from the body of the ferrule.
As previously indicated, some of the components of broadhead 10,
and in particular ferrule 12 and retaining collar 16 may be
manufactured using a powdered metallurgical manufacturing process
resulting in monolithic components. The powdered metallurgical
process permits net shape or near net shape parts which have
intricate design features. Furthermore, the powdered metallurgical
process provides greater control over the shape and weight of the
broadhead, and also improves the overall strength of the broadhead.
The powdered metallurgical process also eliminates many fabricating
and machining steps associated with conventional broadhead
manufacturing.
With references now to FIGS. 9-14, a second preferred embodiment of
the present invention is illustrated in the form of a fixed-blade
broadhead. Broadhead 110 includes ferrule 112, .Iadd.and
.Iaddend.cutting blades 114 releasably secured to ferrule 112. A
conical or trocar shaped tip 118 is threadedly secured at a forward
end of ferrule 112 and functions to releasably secure cutting
blades 114 thereon. The body 120 of ferrule 112 is generally
conically shaped having a triangular cross-section as best seen in
FIG. 10 and has a shank 134 extending rearwardly therefrom. Each of
the vertices 122 of body 120 has a T-shaped .Iadd.slot .Iaddend.124
formed therein which releasably secures cutting blades 114 to
ferrule 112.
Cutting blades 114 have a cutting edge 140 formed along the distal
edge thereof. As best seen in FIG. 13, a bead 142 having a profile
which compliments T-shaped slot 124 is formed along the proximal
edge of cutting blade 114. A generally triangular aperture 144 is
formed in the body of cutting blade 114 to reduce the overall
weight of the broadhead and distribute the mass of the blade around
its perimeter. As presently preferred, cutting blade 114 has a
tapering cross-section from the proximal edge 146 to the distal
cutting edge 140.
Slot 124 is configured to receive the proximal edge 146 of cutting
blade 114 including bead 142. Cutting blade 114 is slid axially
into slots 124 formed in ferrule 112. A threaded shank 148 is
formed on the back surface of broad tip point 118 and is received
in a threaded aperture 152 formed in ferrule 112. In this way,
broadhead tip 118 retains and secures cutting blades 114 with
ferrule 112. While a T-shaped slot configuration and complimentary
bead profile is presently preferred, one skilled in the art will
recognize that other slot configurations and bead profiles (such as
L-shaped, circular, square, etc.) which cooperate to releasably
secure blades 114 to ferrule 112 are contemplated by the present
invention.
Broadhead 110 may be threadedly secured to arrow shaft 154 in the
manner heretofore described. A compliant element (not shown) may be
interdisposed between ferrule 112 and arrow shaft 154 to prevent
loosening therebetween. As presently preferred, blades 114 are
releasably secured to ferrule 112 by tip 118. However, one skilled
in the art will recognize that ferrule 112 could be configured such
that a retaining element disposed over shank 134 or arrow shaft 154
functions to releasably secure blades 114 to ferrule 112.
With reference now to FIG. 11, an alternate embodiment of the
ferrule is illustrated. The body 120' of ferrule 112' is generally
pyramidally shaped having a triangular cross-section as best seen
in FIG. 12. Each of the vertices 122' of body 120' has a slot 124'
formed therein which receives cutting blades 114. The planar
surfaces 121' of body 120' have a generally textured surface formed
thereon for enhancing aerodynamic and penetration properties of the
broadhead. In this regard, U.S. Pat. No. 5,871,410, the disclosure
of which is expressly incorporated by reference herein, discloses a
broadhead in which the ferrule has such a textured surface.
With reference now to FIG. 14, an alternate embodiment of the
cutting blades utilized in the present invention is illustrated.
Specifically, cutting blade 114' is generally triangularly
configured having a cutting edge 140' formed on a distal edge
thereof. In addition, a plurality of scallops or serrations 141'
are formed in the cutting edge to further facilitate cutting of the
broadhead upon impact. Cutting blade 114' further includes a bead
disposed along a proximal edge thereof for releasably securing
blade 114' within ferrule 112 in a manner hereto for described.
With reference now to FIGS. 15 and 16, a general description of a
preferred method of manufacturing a broadhead in accordance with
the present invention will now be described. A more detailed
description is set forth in U.S. application Ser. No. 09/546,146
filed on Apr. 10, 2000 and entitled "Broadhead and Method Of
Manufacture", the disclosure of which is expressly incorporated by
reference herein. The method of manufacture is schematically
illustrated in flow chart 100.
The manufacturing process is initiated by blending metal powder and
binder to form a powdered metal composition as represented at block
102. When blending, the metal powder and binder are typically
premixed in a first blending step 102a and then fully mixed to a
near homogenous mixture and pelletized in a second blending step
102b. In this regard, a particular metal such as high carbon steel
or titanium is mixed with a suitable binder such as a plastic or
wax to form a powdered metal composition. Alternatively, plastic,
ceramic or composite materials suitable for powder injection
molding (PIM) may be substituted for the powdered metal composition
described above. Next, as represented in block 104, the powdered
metal composition is injected into a broadhead mold 105 having the
particular design configurations for fabricating ferrule 12 and
collar 16 illustrated in FIGS. 1-8, or alternately for fabricating
ferrule 112, cutting blade 114 and/or tip 118. One skilled in the
art will recognized that the various PIM components of broadhead
110 are formed separately. Through the use of pressure or other
means, the powdered metal composition is compacted into a greenware
broadband component having the precise geometric configuration of
the final product (although approximately 20% larger than the end
design to account for shrinkage during subsequent processing) and
moderate densification (on the order of approximately 50
densification).
Next, as represented in block 106, the greenware broadhead
component is processed to eliminate the binder from the metal
without melting the constituent metal, thereby forming a powdered
metal broadhead component. As presently preferred, the greenware
broadhead component is immersed in a solvent to separate a portion
of the binder from the powdered metal as illustrated in block 106a.
The greenware broadhead component is removed from the solvent and
placed in a thermal debinding furnace represented at block 106b
where any remaining binder is burned off. The thermal debinding
furnace may also be employed to perform a pre-sintering step. While
the debinding steps is described as a combination of chemical and
thermal processes, one skilled in the art will readily recognize
that any process or combination of processes could be employed to
debind the greenware broadhead. At this point, the powdered metal
broadhead component is still in a moderate densification state.
As represented at block 108, the powdered metal broadhead component
is next placed in a sintering furnace and sintered at an elevated
temperature and pressure to achieve near full density thereof. The
sintering processing parameters are defined such that the broadhead
reaches a density of at least 97%. During the sintering process,
the overall size of the broadhead shrinks approximately 20%. Once
sintering is complete, the broadhead component has a net shape and
does not require further machining. In addition, the various
features including slots, bosses and threaded shanks are already
formed in the ferrule. Lastly, as represented at block 110, cutting
blades are secured to the ferrule in a final assembly process of
the broadhead.
As presently preferred, the broadhead components of the present
invention are fabricated using a powdered metal technology.
However, one skilled in the art will readily recognize that other
powdered materials such as ceramics or plastics may be suitable,
and thus utilized herein. The determination of the exact materials
are dictated by the requirements of a given application.
From the foregoing description, one skilled in the art will readily
recognize that the present invention is directed to an archery
broadhead design and a method of manufacturing same. While the
present invention has been described with particular reference to
preferred embodiments, one skilled in the art will recognize from
the foregoing discussion and accompanying drawings and claims, that
changes, modifications and variations can be made in the present
invention without departing from the spirit and scope thereof as
defined in the following claims.
* * * * *
References