Products and processes for making broadheads of amorphous alloys

Abstract

Embodiments of the present disclosure include broadhead assemblies and components for use with an archery bow and arrow. Embodiments of the present disclosure include products and methods of making broadhead assemblies and components using bulk solidifying amorphous alloys.

What is claimed: 
     
         1 . A method of making a broadhead assembly, comprising:
 a. providing a reusable mold defining an internal mold cavity matching the shape geometry of a broadhead assembly with a ferrule and a plurality of integrated blades with cutting edges, wherein the mold cavity profile net-to-shape size is less than 0.5% larger than the profile of the intended finished broadhead assembly, and wherein the mold defines a passageway to deliver liquid metal from an entry site to the mold cavity;   b. heating a feedstock of metal to a liquid non-crystalline state;   c. injecting the liquid-state non-crystalline metal into the mold cavity via the passageway to fill the mold cavity;   d. rapidly cooling the liquid-state metal to an amorphous non-crystalline solid state;   e. opening the mold and ejecting the finished broadhead assembly; and,   f. sharpening the blade cutting edges.   
     
     
         2 . The method of  claim 1 , wherein the amorphous alloy contains greater than 50% zirconium. 
     
     
         3 . The method of  claim 1 , wherein the mold cavity profile net-to-shape size is less than 0.2% larger than the profile of the intended finished broadhead assembly. 
     
     
         4 . The method of  claim 1 , wherein each blade cutting edge thickness is molded with a radius of approximately 10 microns or less, and wherein the blade cutting edges are sharpened, after ejection, to a final cutting radius of approximately 2.0 microns or less. 
     
     
         5 . The method of  claim 1 , wherein said mold is a two piece mold and said broadhead assembly has two blades. 
     
     
         6 . The method of  claim 1 , wherein said mold is a three piece mold and said broadhead assembly has three blades. 
     
     
         7 . The method of  claim 1 , wherein said mold defines a plurality of parting lines and wherein the shape geometry allows at least 1° clearance around the parting lines. 
     
     
         8 . The method of  claim 1 , comprising applying a partial vacuum to the mold cavity while injecting the liquid-state metal. 
     
     
         9 . The method of  claim 1 , wherein said shape geometry defines dimples in the ferrule portion. 
     
     
         10 . A method of making a broadhead component, comprising:
 a. providing a reusable mold defining an internal mold cavity matching the shape geometry of a broadhead component, wherein the mold cavity profile net-to-shape size less than 0.5% larger than the profile of the intended finished broadhead component, wherein the mold defines a passageway to deliver liquid metal from an entry site to the mold cavity;   b. heating a feedstock of metal to a liquid non-crystalline state;   c. injecting the liquid-state non-crystalline metal into the mold cavity via the passageway to fill the mold cavity;   d. rapidly cooling the liquid-state metal to an amorphous non-crystalline solid state;   e. opening the mold and ejecting the finished broadhead component.   
     
     
         11 . The method of  claim 10 , where the broadhead component is a ferrule. 
     
     
         12 . The method of  claim 10 , where the broadhead component is a blade. 
     
     
         13 . The method of  claim 12 , wherein the broadhead component is a blade with at least one cut-out portion. 
     
     
         14 . The method of  claim 13 , wherein the blade defines cross-members which sub-divide the cut-out portion into smaller openings. 
     
     
         15 . A method of making a broadhead component, comprising:
 a. defining a shape geometry for a broadhead component;   b. using the shape geometry to determine the location for at least one parting line for at least one of a pattern, die or mold;   c. creating at least one of a pattern, die or mold defining a plurality of internal mold cavities matching the shape geometry of a broadhead component;   d. heating a feedstock of metal to a liquid non-crystalline state;   e. injecting the liquid-state non-crystalline metal into said mold cavities under positive pressure to fill the mold cavities;   f. rapidly cooling the liquid-state metal to an amorphous non-crystalline solid state; and,   g. opening the at least one of a pattern, die or mold along the at least one parting line and ejecting a plurality of finished broadhead components from the mold cavities.   
     
     
         16 . The method of  claim 15 , wherein the mold cavity profiles are less than 0.2% larger that the profiles of the finished broadhead component. 
     
     
         17 . The method of  claim 16 , wherein the shape geometry is a blade with a cutting edge, and comprising sharpening the cutting edges of said plurality of finished broadhead components to a final cutting radius of approximately 2.0 microns or less. 
     
     
         18 . The method of  claim 16 , wherein the broadhead component is a ferrule with a length, and wherein the cross-sectional area varies along the length of the ferrule. 
     
     
         19 . The method of  claim 16 , wherein the broadhead component is a ferrule and wherein said shape geometry defines dimples in the ferrule. 
     
     
         20 . The method of  claim 15 , comprising applying a partial vacuum to said plurality of mold cavities while injecting the liquid-state metal.