GB2149332A

GB2149332A - Die casting method of manufacturing one-piece hollow article, such as metal "wood" head of golf club

Info

Publication number: GB2149332A
Application number: GB08329262A
Authority: GB
Inventors: Hou Cheng Lee
Original assignee: Individual
Current assignee: Individual
Priority date: 1983-11-02
Filing date: 1983-11-02
Publication date: 1985-06-12
Also published as: GB8329262D0

Abstract

The method comprises the steps of manufacturing a hollow core (4) by die casting e.g. aluminium, filling the hollow core (4) with a mixture of resin and sand, then heating the hollow core so as to solidify the mixture, die- casting further molten metal around the filled core and polishing the exterior of the casting. The resin is gasified, so that the sand can be loosened by tapping the article and then poured out through the hollow stem (41). <IMAGE>

Description

SPECIFICATION Die casting method of manufacturing onepiece hollow jar-like article, such as metal "wood" head of club The present invention relates to a die casting method of manufacturing one-piece hollow jar-like article, such as metal "wood" head of club and in particular to one which may increase the rate of successfully manufacturing a product and improve the physical properties of the product.

With reference to Fig. 6 and Fig. 7, the known method for producing a metal wood head of a club comprises the steps of: 1/. manufacturing a head (a) by casting; 2/. manufacturing a cover (b) by casting; 3/. joining together the head (a) and the cover (b) by welding; 4/. grinding to remove the unsightly mark (c) left by welding; 5/. polishing the contour of the metal wood head of club constituted by the head (a) and the cover (b).

However, the known method for producing metal wood head of club has long suffered from the following drawbacks: 1/. Since the head (a) and the cover (b) are made of aluminum which has poor weldability, the physical properties of the metal wood head produced is decreased.

2/. After grinding the unsightly mark (c) left by welding, most metal wood heads produced will have pores at the welded junction.

3/. Since the rate of successfully manufacturing a metal wood head of club is low, the manufacturing cost will be increased.

4/. The manufacturing process is complicated, so that the manufacturing cost is high.

Thus, the inventor of the present invention creates a method which may obviate and mitigate the drawbacks mentioned above through numerous experiments.

It is a primary object of the present invention to provide a die casting method of manufacturing one-piece hollow jar-like article whereby the manufacturing cost is decreased.

It is another object of the present invention to provide a die casting method of manufacturing one-piece hollow jar-like article whereby the rate of successfully manufacturing a product is increased.

It is a further object of the present invention to provide a die casting method of manufacturing one-piece hollow jar-like article whereby the physical properties of product may be improved.

Furthermore, the present invention may offer the following advantages: 1/. The method according to the present invention is not so complicated as the prior art method so that the manufacturing cost may be decreased.

2/. The product produced by the method according to the present invention does not have pores, thereby increasing the rate of successfully manufacturing a product and therefore, decreasing the manufacturing cost.

3/. Since the product produced by the method according to the present invention is of a unitary structure, the physical properties of the product must be better than those of the article produced by prior art method.

4/. The mixture of resin and sand is inexpensive and will not influence the manufacturing cost.

5/. The method according to the present invention does not have the steps of welding and grinding which are required in carrying out the prior art method and must be achieved by skilled technicians, thus facilitating the procedure for production.

6. The method for producing a product by means of two times of die casting is indeed an innovation.

7/. The method according to the present invention not only can be used for manufacturing metal wood head, but also for similar article Other objects and merits and a fuller understanding of the present invention will be obtained by those skilled in the art when the following detailed description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings wherein like numerals refer to like or similar parts and in which:: Figure 1 is a fiow chart showing the procedures of a die casting method of manufacturing one-piece hollow jar-like article according to the present invention; Figure 2 shows a set of moulds served to carry out the method according to the present invention; Figure 3 is a perspective view of a hollow core produced by the moulds shown in Fig. 2; Figure 4 shows a set of moulds served to cast the contour of the hollow core; Figure 5 is a perspective view of a metal wood head of club produced by the method according to the present invention; Figure 6 is a flow chart showing the prior art procedures for producing a metal wood head of club.

Figure 7 is a fragmentary perspective view of a prior art metal wood head of club; and Figure 8 is a perspective view of the prior art metal wood head of club.

With reference to Fig. 1, the die casting method for manufacturing a metal wood head of club according to the present invention comprises the steps of: 1/. manufacturing a hollow core; 2/. filling the hollow core with a mixture of resin and sand and then heating the hollow core so as to solidfy the mixture; 3/. manufacturing the contour of the hollow core by die casting; and 4/. polishing the contour of the hollow core.

The above-mentioned four steps will be detailedly described as follows: Step 1: Turning to Fig. 2, there is shown a first set of moulds (1) and (2) for manufacturing a hollow core. The mould (1) is provided with a cavity (11), a gate (12) connected to the cavity (11), and a cylinder (13).

The cylinder (1 3) is equipped with a sliding rod (131) disposed into a neck (111) of the cavity (11) and a rectangular end. The sliding rod (131) of the cylinder (13) may slide into or out of the neck (111) along the directions indicated by an arrow (31). At an abdomen (112) of the cavity (11) is mounted a sliding block (14) which may slide into or out of the abdomen (112) along the directions indicated by an arrow (32). Furthermore, the mould (2) comes with a cavity (21).

To cast an hollow core (4), first close to getter the moulds (1) and (2) in the manner that a space is formed between the cavity (11) and the cavity (21). Then, pour liquid aluminum (about 680"C-710"C) or the like into the space formed between the cavities (11) and (21) from the gate (12). When the aluminum filled into the space therein is solidified.

remove the sliding rod (131) and the sliding block (14) from the neck (111) and the abdomen (11 2) respectively, and separate the mould (2) from the mould (1). Then, this step is finished by taking out the cast aluminum block (4) shown in Fig. 3 from the mould (1).

The cast aluminum block (4) is called the hollow core (4). The method for producing the hollow core (4) by means of the moulds (1) and (2) is commonly called die casting.

Step 2: Fill the interior (42) of the hollow core (4) shown in Fig. 3 with a mixture of sand and resin.

The mixture of sand and resin is available on the market, which exists as a solid at 400'C. The resin of the mixture will be gasified at 700'C, thereby only leaving the sand of the mixture. Once the resin of the mixture is gasified, the mixture cannot go back to its original state even though it is cooled to the room temperature.

In step 2, the mixture of resin and sand is first filled into the interior (42) of the hollow core (4) and then the hollow core (4) is heated to 400'C so as to solidify the mixture.

Referring to Fig. 4, there is shown a second set of moulds (5) and (6) for manufacturing the contour of the hollow core (4). As shown, the mould (5) is provided with a cavity (51), a cylinder (52), and a gate (53) connected to the cavity (51).

The cylinder (52) is equipped with a sliding rod (521) disposed into neck (511) of the cavity (51). Furthermore, the sliding rod (521) is provided with a rectangular end and may slide into or out of the neck (511) along the directions indicated by an arrow (33).

The mould (6) comes with a cavity (61).

The cavities (51) and (61) are slightly larger than the cavities (11) and (21) respectively.

Then insert the sliding rod (521) into the neck (41) of the hollow core (4), thereby confining the hollow core (4) into the cavity (51).

Step 3: Place the hollow core (4) which has been filled with mixture of resin and sand and heated to 400'C into the cavity (51). Close together the moulds (5) and (6) in such a way that a space is formed between the cavity (51) and the cavity (61). The space therein is slightly larger than the space formed between the cavity (11) of the mould (1) and the cavity (21) of the mould (2). Pour liquid aluminum approximately at 710'C or the like into the space formed between the cavity (51) and the cavity (61) from a gate (53), thereby enclosing the hollow core (4) with a layer of aluminum. Since the liquid aluminum is approximately at 710"C, the resin of the mixture filled into the interior (42) of the hollow core (4) is gasified. When the contour of the hollow core (4) is cooled, take out the sliding rod (521) from the neck (511), separate the mould (6) from the mould (5), and remove the metal wood head (7). Then tap the metal wood head (7) at its abdomen (72) to power the mixture therein so as to let out the mixture, thus resulting in a one-piece hollow metal wood head.

Step 4: Polish the contour of the metal wood head.

Although this invention has been described with a certain degree of particularity, it is understood that the present disclosure is made by way of example only and that numerous changes in the detail of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter

Claims

claimed. CLAIMS

1. Die casting method of manufacturing one-piece hollow jar-like article comprising the steps of: a/. manufacturing a hollow core by die casting; b/. filling the interior of said hollow core with a mixture resin and sand and then heating said hollow core so as to solidify said mixture therein: c/. placing said hollow core into a set of moulds which is slightly larger than said hollow core and then pouring liquid aluminum of which the temperature will gasify the resin of said mixture into said set of moulds, thereby forming a contour of said hollow core; and d/. polishing said contour of said hollow core.

2. Die casting method according to claim 1, substantially as herein described with reference to the accompanying drawings.