Unitary broadhead blade unit

Abstract

A unitary blade unit for an archery broadhead includes a tip structure and blades inseparably connected into a single blade unit. The blade unit is made by molding such as metal injection molding or laser welding.

1 . A method of manufacturing a unitary blade unit for a modular broadhead, comprising: 
 providing a mold having one or more cavities that define a multiple-bladed blade unit;    inserting a mixture of metal and binder into the mold;    compacting the mixture in the mold to form an intermediate blade unit;    processing the intermediate blade unit to remove at least a portion of the binder;    sintering the intermediate blade unit to form a sintered blade unit; and    sharpening the blades to form a cutting edge on each blade to yield a final blade unit, wherein the final blade unit requires a separate ferrule in order to attach to an arrow.    
   
   
       2 . The method of  claim 1  wherein the mixture is in powdered form.  
   
   
       3 . The method of  claim 1  wherein the sintering step comprises sintering at an elevated temperature and pressure.  
   
   
       4 . A method of manufacturing a blade unit for a modular broadhead, comprising using metal injection molding to form a blade unit from a mixture that includes metal and a binder, wherein the blade unit has at least two blades and requires a separate ferrule in order to attach to an arrow.  
   
   
       5 . The method of  claim 4  further comprising manufacturing a separate adapter for securing the blade unit to the ferrule.  
   
   
       6 . The method of  claim 4  wherein the method includes forming the blade unit to include a first integral adapter for securing the blade unit to the ferrule.  
   
   
       7 . The method of  claim 4  wherein the method further includes manufacturing a second separate adapter for further securing the blade unit to the ferrule.  
   
   
       8 . A method of manufacturing a blade unit for a modular broadhead, the method comprising: 
 arranging a plurality of components in the form of a blade unit for a modular broadhead; and    directing an energy beam toward a plurality of contact segments to weld the plurality of components into a blade unit, wherein each contact segment comprises a location where at least two of the plurality of components are in contact.    
   
   
       9 . The method of  claim 8  wherein the plurality of components comprises a plurality of blades.  
   
   
       10 . The method of  claim 9  wherein the plurality of components further comprises a cap structure for receiving a separable ferrule.  
   
   
       11 . The method of  claim 9  wherein the plurality of components further comprises a collar structure for receiving a separable ferrule.  
   
   
       12 . The method of  claim 9  wherein the plurality of components further comprises a tip structure.  
   
   
       13 . The method of  claim 8  wherein the energy beam is a laser.  
   
   
       14 . The method of  claim 8  wherein directing an energy beam comprises performing laser welding.  
   
   
       15 . The method of  claim 8  wherein directing an energy beam comprises focusing the energy beam toward a contact segment using a device.  
   
   
       16 . The method of  claim 8  wherein the device comprises one or more of a focus cell, a lens, and a mirror.  
   
   
       17 . The method of  claim 8  wherein directing an energy beam comprises moving a focal point of the energy beam along a contact segment in a direction from a tip of the blade unit to a base of the blade unit.  
   
   
       18 . The method of  claim 8  wherein a plurality of energy beams are directed toward a plurality of contact segments simultaneously, wherein each energy beam is directed toward a particular contact segment.