Metal Injection Molded Putter with Internal Frame
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Solution Overview
Problem
Current methods for manufacturing golf clubs, such as forging or casting, are time-consuming, inefficient, and expensive, particularly due to the high cost of powdered metals required for metal injection molding processes.
Innovation Solution
The process involves using a frame made of stainless steel, titanium, or aluminum alloys within a mold where a combination of powdered metal and a binding agent is injected, followed by solvent washing and sintering to reduce material usage and costs, with optional voids in the mold design to further minimize powdered metal requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the entire volume of the club head is formed from powdered metal using metal injection molding, then the golf club achieves strength and integrity similar to machined parts, but the cost becomes prohibitive due to the high cost of powdered metals
Solution Approach 1:
The patent applies composite materials by combining powdered metal with a binding agent to form a feedstock mixture. This composite approach allows the use of less expensive powdered metal while maintaining structural integrity through the binding agent, directly resolving the contradiction between strength requirements and powdered metal cost
Solution Approach 2:
The invention segments the club head into different material zones: a powdered metal component formed by injection molding and a separate binding agent matrix. This segmentation allows the expensive powdered metal to be used only where structural strength is critical, while other areas use the more economical binding agent, reducing overall material cost while maintaining necessary strength
2Reliability
If traditional forging or casting methods are used to manufacture golf clubs, then the process is well-established, but the manufacturing process becomes time-consuming and inefficient
Solution Approach 1:
The patent replaces traditional mechanical forging or casting processes with metal injection molding. This substitution enables automated, high-volume production through injection molding technology while maintaining reliable product quality, directly addressing the contradiction between process reliability and manufacturing efficiency
Solution Approach 2:
The invention changes the fundamental manufacturing parameter from solid-state forging or molten metal casting to a slurry-based injection molding process. This parameter change enables the use of standard plastic injection molding equipment, dramatically improving productivity while maintaining process reliability through established molding techniques
3Quantity of substance
If a frame is positioned in a mold and powdered metal is injected around it, then the volume of powdered metal required is reduced, but the process complexity increases
Solution Approach 1:
The patent applies nesting by placing a frame structure inside the mold cavity before injecting the powdered metal feedstock. The frame acts as a core around which the powdered metal is deposited, reducing the total volume of powdered metal needed while simplifying the overall mold design through this nested configuration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces material costs and increases efficiency by minimizing the volume of powdered metal needed, achieving a cost-effective and aesthetically pleasing golf club head with improved manufacturing complexity and reduced need for secondary finishing operations.
Implementation Method 1
The molded product or 'green part' is removed from the mold and washed with a solvent to remove the binding agent.
Implementation Method 2
The washed product is then subjected to a sintering process to further remove the binding agent and to fuse the metal particles together.
Implementation Method 3
combining fine metal powders of a diameter of less than 45 micrometers with plastic binders
Data Source
AI summary
The present invention relates to a method for forming golf club head using metal injection molding and the resulting golf club head. The method of the invention allows for a lower volume of powdered metal than current metal injection molding processes thereby decreasing overall production cost.