(12) United States Patent
`(12) United States Patent
`Marx et al.
`Marx et ai.
`
`111111
`
`1111111111111111111111111111111111111111111111111111111111111
`US006547210B1
`US006547210Bl
`(10) Patent No.:
`US 6,547,210 B1
`US 6,547,210 Bl
`(10) Patent No.:
`(45) Date of Patent:
`Apr. 15, 2003
`Apr.1S,2003
`(45) Date of Patent:
`
`EP
`EP
`EP
`H.
`FR
`JP
`JP
`WO
`WO
`WO
`WO
`
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`() 466 664 A 9/1991
`0466664 A
`9/1991
`9/2000
`1033 193 A
`1 * º º
`3/1977
`2321378 A
`()7 304057
`11/1995
`11/1995
`07304057
`WO 90 08637 A 8/1990
`8/1990
`WO 90 08637 A
`WO 93 17820 A 9/1993
`9/1993
`WO 9317820 A
`OTHER PUBLICATIONS
`OTHER PUBLICATIONS
`Jack Avery, “Section 5.5: Multicomponent Molding,” Injec
`Jack Avery, "Section 5.5: Multicomponent Molding," Injec(cid:173)
`tion Molding Alternatives: A Guide for Designers and
`tion Molding Alternatives: A Guide for Designers and
`Product Engineers, Hanser Gardner Publishers, 1998, pp.
`Product Engineers, Hanser Gardner Publishers, 1998, pp.
`113–117.
`113-117.
`
`(54) SACRIFICIAL INSERT FOR INJECTION
`(54) SACRIFICIAL INSERT FOR INJECTION
`MOLDING
`MOLDING
`(75) Inventors: Jeffrey G. Marx, Downingtown, PA
`(75)
`Inventors: Jeffrey G. Marx, Downingtown, PA
`(US); Bradley R. Heckendorf,
`(US); Bradley R. Heckendorf.
`Menomonie, WI (US); Brian L.
`Menomonie, WI (US); Brian L.
`Norberg, Durand, WI (US)
`Norberg, Durand, WI (US)
`(73) Assignee: Wright Medical Technology, Inc.,
`Assignee: Wright Medical Technology, Inc.,
`(73)
`Arlington, TN (US)
`Arlington, TN (US)
`Subject to any disclaimer, the term of this
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`U.S.c. 154(b) by 0 days.
`(21) Appl. No.: 09/505,962
`(21) Appl. No.: 09/505,962
`(22) Filed:
`Feb. 17, 2000
`(22) Filed:
`Feb. 17,2000
`(51) Int. Cl." .................................................. B28B 728
`(51)
`Int. CI? .................................................. B28B 7/28
`(52) U.S. Cl. .......................................... 249/175; 249/63
`(52) U.S. CI. .......................................... 249/175; 249/63
`(58) Field of Search ............................ 249/63, 64, 175;
`(58) Field of Search ............................ 249/63, 64, 175;
`264/317
`264/317
`
`(*) Notice:
`( * )
`Notice:
`
`(56)
`(56)
`
`(List continued on next page.)
`(List continued on next page.)
`Primary Examiner—Christopher A. Fiorilla
`Primary Examiner-Christopher A. Fiorilla
`ABSTRACT
`°7)
`ABSTRACT
`(57)
`Sacrificial inserts and molds for use in injection molding &l?º
`Sacrificial inserts and molds for use in injection molding are
`disclosed. In one embodiment a sacrificial insert includes a
`disclosed. In one embodiment a sacrificial insert includes a
`water-insoluble insert which has a melting temperature
`water-insoluble insert which has a melting temperature
`9.
`p
`greater than the injection molding melt temperature of the
`e
`greater than the injection molding melt temperature of the
`References Cited
`base material being molded. In another embodiment, a mold
`References Cited
`base material being molded. In another embodiment, a mold
`includes one or more of a sacrificial insert configured to
`U.S. PATENT DOCUMENTS
`includes one or more of: a sacrificial insert configured to
`gu
`U.S. PATENT DOCUMENTS
`form interior features of the object; a sacrificial insert
`form interior features of the object; a sacrificial insert
`3,731,901 A 5/1973 Holdredge, Jr. ............. 249/180
`3,731,901 A
`5/1973 Holdredge, Jr .............. 249/180
`configured to form interior and exterior features of the
`3,882,220 A
`5/1975 Ryder ......................... ... configured to form interior and exterior features of the
`3,882,220 A
`5/1975 Ryder ......................... 264/221
`a?oodoss A
`6/1978 Wolf
`object; and a combination of a sacrificial insert configured to
`object; and a combination of a sacrificial insert configured to
`4,094,688 A
`6/1978 Wolf
`4343,757 A.
`8/1982 Popplewell ................. 264/221
`form exterior features of the object and a tool configured to
`form exterior features of the object and a tool configured to
`4,343,757 A
`8/1982 Popplewell ................. 264/221
`form interior features of the object. In another embodiment,
`4,464,324 A 8/1984 Hager ..........
`.... 264/221
`form interior features of the object. In another embodiment,
`4,464,324 A
`8/1984 Hager ........................ 264/221
`a multi-shot injection molding process includes: providing a
`4,614,627 A 9/1986 Curtis et al. ...
`... 264/46.6
`a multi-shot iniection molding process includes: providing a
`4,614,627 A
`9/1986 Curtis et al. ............... 264/46.6
`2- - - 2
`J
`g p
`p
`9.
`4,743,481 A 5/1988 Quinlan et al. ............... 428/36
`support base containing a tool; injecting a first material into
`support base containing a tool; injecting a first material into
`4,743,481 A
`5/1988 Quinlan et al. ............... 428/36
`4,752,857 A * 6/1988 Khoury et al. .............. 361/321
`4,752,857 A * 6/1988 Khoury et al. .............. 361/321
`the support base to form an integral tool and sacrificial
`the support base to form an integral tool and sacrificial
`4,827,589 A
`5/1989 Friedrichs .............. 29/156.4 R
`4,827,589 A 5/1989 Friedrichs .....
`... 29/156.4 R
`insert; separating the tool from the sacrificial insert; retain
`insert; separating the tool from the sacrificial insert; retain(cid:173)
`4,870,148 A
`9/1989 Belz et al. ............. 526/318.41
`?º º
`tº. º et al. .
`- - sº:* ing the sacrificial insert in the support base, or inserting the
`ing the sacrificial insert in the support base, or inserting the
`4,891,175 A
`1/1990 Haines ....................... 264/154
`2- - -->
`/
`
`anes … / sacrificial insert into another support base optionally having
`sacrificial insert into another support base optionally having
`4,938,679 A
`7/1990 Pietrorazio .................. 425/437
`4,938,679 A 7/1990 Pietrorazio .................. 425/437
`- - - - -
`-
`-
`- -
`-
`a further sacrificial insert or tool; injecting a second material
`4.956,142 A
`9/1990 Mangone, Jr
`264/318
`a further sacrificial insert or tool; injecting a second material
`4,956,142 A
`9/1990 Mangone, Jr ............... 264/318
`4900146 A 2/1991 Deibig et al... ... Soiss;
`into the support base containing the sacrificial insert to form
`into the support base containing the sacrificial insert to form
`4,990,146 A
`2/1991 Deibig et al. ............... 604/332
`an integral sacrificial insert and molded object; and destruc(cid:173)
`5,089,186 A 2/1992 Moore et al. ................. 264/25
`an integral sacrificial insert and molded object; and destruc
`5,089,186 A
`2/1992 Moore et al. ................. 264/25
`5,143,665 A 9/1992 Clubbs et al. .............. 264/221
`tively disengaging the sacrificial insert from the molded
`tively disengaging the sacrificial insert from the molded
`5,143,665 A
`9/1992 Clubbs et al.
`.............. 264/221
`5,169,577. A 12/1992 Feichtinger
`object without substantially damaging the molded object. In
`object without substantially damaging the molded object. In
`5,169,577 A
`12/1992 Feichtinger
`5,173,237 A 12/1992 Kidd .......................... 264/221
`another embodiment, a sacrificial insert is used to injection
`5,173,237 A
`12/1992 Kidd .......................... 264/221
`another embodiment, a sacrificial insert is used to injection
`5,176,866 A
`1/1993 Tanaka et al.
`.............. 264/219
`5,176,866 A 1/1993 Tanaka et al. ....
`... 264/219
`mold a metal or ceramic object.
`mold a metal or ceramic object.
`5,242,646 A 9/1993 Torigoe et al. ............. 264/219
`5,242,646 A
`9/1993 Torigoe et al.
`............. 264/219
`(List continued on next page.)
`(List continued on next page.)
`
`1 Claim, 1 Drawing Sheet
`1 Claim, 1 Drawing Sheet
`
`
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1007-0001
`
`

`

`US 6,547,210 Bl
`US 6,547,210 B1
`Page 2
`Page 2
`
`5,997,230 A 12/1999 Dodd et al. ................. 411/383
`U.S. PATENT DOCUMENTS
`U.S. PATENT DOCUMENTS
`5,997,230 A
`12/1999 Dodd et al. ................. 411/383
`OTHER PUBLICATIONS
`OTHER PUBLICATIONS
`5,248,552 A 9/1993 Moore et al. ............... 428/323
`9/1993 Moore et al. ............... 428/323
`5,248,552 A
`10/1993 Burkarth et al.
`5,249,618 A
`Mike Tolinski, “Process Selection for Multi-Shot Molding,”
`5,249,618 A 10/1993 Burkarth et al.
`Mike Tolinski, "Process Selection for Multi-Shot Molding,"
`7/1995 Schulz et al. ............ 264/297.2
`5,433,912 A
`-
`5,433,912 A 7/1995 Schulz et al. ............ 264/297.2
`Molding Systems, vol. 56, No. 1, Jan. 1998, pp. 30–35.
`Molding Systems, vol. 56, No.1, Jan. 1998, pp. 30-35.
`1/1997 Foltuz et al.
`............... 425/443
`5,595,771 A
`& 4
`-
`-
`-
`-
`33
`5,595,771 A
`1/1997 Foltuz et al. .....
`... 425/443
`"Choosing a Multi-Material Molding Process".
`Choosing a Multi-Material Molding Process".
`5,614,232 A
`3/1997 Torigoe et al. ............. 425/545
`3/1997 Torigoe et al.
`............. 425/545
`5,614,232 A
`P. Coates, "Multi-Shot Values," Plastics and Rubber
`P. Coates, “Multi-Shot Values,” Plastics and Rubber
`5,630,977. A
`5/1997 Catalanotti et al. ......... 264/318
`5/1997 Catalanotti et al. ......... 264/318
`5,630,977 A
`Weekly, No. 1789, Jun. 4, 1999, p. 7.
`Weekly, No. 1789, Jun. 4, 1999, p. 7.
`5,656,234 A 8/1997 Kaneishi et al. ............ 264/572
`8/1997 Kaneishi et al. ............ 264/572
`5,656,234 A
`J. Hahn, "Case Study for Multi-Shot," Antec *99 Confer(cid:173)
`J. Hahn, “Case Study for Multi-Shot,” Antec *99 Confer
`5,658,515 A 8/1997 Lee et al. ......
`... 264/219
`8/1997 Lee et al.
`................... 264/219
`5,658,515 A
`ence Proceedings, New York City, May 2–6, 1999, pp.
`5,681,518 A 10/1997 Ashcraft .......
`.... 264/221
`ence Proceedings, New York City, May 2-6, 1999, pp.
`10/1997 Ashcraft ..................... 264/221
`5,681,518 A
`406—410.
`5,702,660 A 12/1997 Allott et al. ...
`... 264/242
`12/1997 Allott et al.
`................ 264/242
`5,702,660 A
`406-410.
`§: º ". | Wººl al. .......... sº J. Tinson, “Multi-Shot Injection Moulding,” Medical
`10/1998 Whalen et al.
`............. 264/219
`5,824,250 A
`J. Tinson, "Multi-Shot Injection Moulding," Medical
`3/1999 Liu et al. ............... 29/898.066
`5,878,496 A
`Device Technology, No.3, Apr. 1998, pp. 26-28.
`5,906,234. A
`5/1999 Mastrorio et al. ............ º: Device Technology, No.3, Apr 1998, pp. 26–28.
`5/1999 Mastrorio et al.
`............ 164/45
`5,906,234 A
`* cited by examiner
`* 10/1999 Barros et al. ............... 264/221
`5,972,269 A * 10/1999 Barros et al. ............... 264/221
`* cited by examiner
`5,972,269 A
`
`Ill CI al. ...............
`
`2- - -->
`
`
`
`-
`
`-
`
`-
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1007-0002
`
`

`

`u.s. Patent
`U.S. Patent
`
`
`
`Apr. 15, 2003
`Apr. 15, 2003
`
`US 6,547,210 B1
`US 6,547,210 Bl
`
`Figure 1"
`
`&
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1007-0003
`
`

`

`1
`1
`SACRIFICIAL INSERT FOR INJECTION
`SACRIFICIAL INSERT FOR INJECTION
`MOLDING
`MOLDING
`
`US 6,547,210 B1
`US 6,547,210 Bl
`
`2
`2
`which uses a fusible core which can be melted out after the
`which uses a fusible core which can be melted out after the
`injected material sets. U.S. Pat. No. 5,143,665 to Cubbs et
`injected material sets. U.S. Pat. No. 5,143,665 to Cubbs et
`al. describe a sacrificial mold used to mold composite
`al. describe a sacrificial mold used to mold composite
`materials, plastic or metals.
`materials, plastic or metals.
`There is a need, however, for a molding system which
`There is a need, however, for a molding system which
`utilizes a sacrificial insert which is capable of forming
`utilizes a sacrificial insert which is capable of forming
`interior features of an injection molded article, and which is
`interior features of an injection molded article, and which is
`able to maintain fidelity of the features being molded under
`able to maintain fidelity of the features being molded under
`the conditions of injection molding. There is also a need for
`the conditions of injection molding. There is also a need for
`a mold combination which can use different combinations of
`10 a mold combination which can use different combinations of
`10
`sacrificial parts and permanent parts to provide optimum
`sacrificial parts and permanent parts to provide optimum
`economy when molding articles, particularly articles having
`economy when molding articles, particularly articles having
`complex geometries which are difficult to mold with con
`complex geometries which are difficult to mold with con(cid:173)
`ventional molds, such as those described above and short
`ventional molds, such as those described above and short-
`run or prototype molded objects. There is also a need for a
`15 run or prototype molded objects. There is also a need for a
`15
`multi-shot process which can economically produce short
`multi-shot process which can economically produce short
`run parts having complex features not normally attainable
`run parts having complex features not normally attainable
`with conventional multi-shot molds.
`with conventional multi-shot molds.
`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`One object of the invention is to overcome the disadvan
`One object of the invention is to overcome the disadvan(cid:173)
`tages of the known art described above. Another object of
`tages of the known art described above. Another object of
`the invention is to provide a sacrificial insert for injection
`the invention is to provide a sacrificial insert for injection
`molding an object, and a mold which includes the sacrificial
`molding an object, and a mold which includes the sacrificial
`insert. Yet another object is to provide a method of injection
`insert. Yet another object is to provide a method of injection
`molding an object using a sacrificial insert. Still another
`molding an object using a sacrificial insert. Still another
`object of the invention is to provide a method for producing
`object of the invention is to provide a method for producing
`an object by multi-shot injection molding the object using a
`an object by multi-shot injection molding the object using a
`sacrificial insert. Yet another object of the invention is to
`sacrificial insert. Yet another object of the invention is to
`provide a method for forming a molded ceramic object or a
`provide a method for forming a molded ceramic object or a
`molded metal object by injection molding using a sacrificial
`molded metal object by injection molding using a sacrificial
`insert.
`insert.
`In order to achieve the foregoing and further objects, there
`In order to achieve the foregoing and further objects, there
`has been provided according to one aspect of the invention,
`has been provided according to one aspect of the invention,
`a sacrificial insert for injection molding an object from a
`a sacrificial insert for injection molding an object from a
`base material, which includes, a water-insoluble insert
`base material, which includes, a water-insoluble insert
`which has a melting temperature greater than the injection
`which has a melting temperature greater than the injection
`molding melt temperature of the base material. According to
`molding melt temperature of the base material. According to
`another aspect of the invention, there has been provided a
`another aspect of the invention, there has been provided a
`mold for making an object by injection molding, which
`mold for making an object by injection molding, which
`includes, a support base and the sacrificial insert described
`includes, a support base and the sacrificial insert described
`above, and optionally a tool.
`above, and optionally a tool.
`According to yet another aspect of the invention, there has
`According to yet another aspect of the invention, there has
`been provided a method of injection molding an object
`been provided a method of injection molding an object
`formed of a base material, which includes: providing a mold
`45 formed of a base material, which includes: providing a mold
`45
`having the sacrificial insert described; providing the base
`having the sacrificial insert described; providing the base
`material in a flowable state; flowing the base material into
`material in a flowable state; flowing the base material into
`the mold and into contact with the sacrificial insert; solidi
`the mold and into contact with the sacrificial insert; solidi(cid:173)
`fying the base material in the mold to form the molded
`fying the base material in the mold to form the molded
`object; and destructively disengaging the sacrificial insert
`50 object; and destructively disengaging the sacrificial insert
`50
`from the molded object without substantially damaging the
`from the molded object without substantially damaging the
`molded object.
`molded object.
`According to still another aspect of the invention, there
`According to still another aspect of the invention, there
`has been provided a method of removing a sacrificial insert
`has been provided a method of removing a sacrificial insert
`from a molded object, which includes, subjecting the sac
`55 from a molded object, which includes, subjecting the sac(cid:173)
`55
`rificial insert described above and the molded object to a
`rificial insert described above and the molded object to a
`treatment sufficient to destroy the sacrificial insert and
`treatment sufficient to destroy the sacrificial insert and
`enable it to be removed from the molded object without
`enable it to be removed from the molded object without
`substantially damaging the molded object.
`substantially damaging the molded object.
`According to a further aspect of the invention, there has
`According to a further aspect of the invention, there has
`been provided a mold for making an object by injection
`been provided a mold for making an object by injection
`molding comprising one or more of: a sacrificial insert
`molding comprising one or more of: a sacrificial insert
`configured to form interior features of the object; a sacrifi
`configured to form interior features of the object; a sacrifi(cid:173)
`cial insert configured to form interior and exterior features of
`cial insert configured to form interior and exterior features of
`the object; and a combination of a sacrificial insert config
`65 the object; and a combination of a sacrificial insert config(cid:173)
`65
`ured to form exterior features of the object and a tool
`ured to form exterior features of the object and a tool
`configured to form interior features of the object.
`configured to form interior features of the object.
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`5
`
`20
`20
`
`1. Field of the Invention
`1. Field of the Invention
`The present invention relates to injection molding in
`The present invention relates to llljection molding in
`general, and in particular to molding with sacrificial inserts,
`general, and in particular to molding with sacrificial inserts,
`particularly for ceramic and metals.
`particularly for ceramic and metals.
`2. Description of the Known Art
`2. Description of the Known Art
`Injection molding is used to manufacture articles of
`Injection molding is used to manufacture articles of
`complex geometry. This method is useful for plastic parts as
`complex geometry. This method is useful for plastic parts as
`well as metal and ceramic parts prepared by powder injec
`well as metal and ceramic parts prepared by powder injec(cid:173)
`tion molding. Injection molding while being generally eco
`tion molding. Injection molding while being generally eco(cid:173)
`nomical for large volumes of parts can be uneconomical for
`nomical for large volumes of parts can be uneconomical for
`short-run or prototype production. Moreover, obtaining cer
`short-run or prototype production. Moreover, obtaining cer(cid:173)
`tain features such as undercuts and blind holes in certain
`tain features such as undercuts and blind holes in certain
`orientations in an injection molded part is either difficult or
`orientations in an injection molded part is either difficult or
`impossible, or requires complex and expensive tooling.
`impossible, or requires complex and expensive tooling.
`There are numerous examples of the use of complex
`There are numerous examples of the use of complex
`tooling solutions such as expanding cores, see, e.g., Holdred,
`tooling solutions such as expanding cores, see, e.g., Holdred,
`“Expandable Core Assembly,” U.S. Pat. No. 3,731,901;
`"Expandable Core Assembly," U.S. Pat. No. 3,731,901;
`Catalanotti, and Tarahomi, “Injection molding method and
`Catalanotti, and Tarahomi, "Injection molding method and
`25
`system with expandable cavity element,” U.S. Pat. No.
`system with expandable cavity element," U.S. Pat. No. 25
`5,630,977; Pietrorazio, “Collapsible core for molding clo
`5,630,977; Pietrorazio, "Collapsible core for molding clo(cid:173)
`sures having interrupted interior threads and the like,” U.S.
`sures having interrupted interior threads and the like," U.S.
`Pat. No. 4,938,679; and Mangone, “Apparatus and method
`Pat. No. 4,938,679; and Mangone, "Apparatus and method
`for molding three dimensional articles,” U.S. Pat. No. 4,956,
`for molding three dimensional articles," U.S. Pat. No. 4,956,
`30
`142, and slides, e.g., Schulz, Kaiser, and Temesvary, “Pro
`142, and slides, e.g., Schulz, Kaiser, and Temesvary, "Pro- 30
`cess for injection molding arcuately-shaped hollow articles,”
`cess for injection molding arcuately-shaped hollow articles,"
`U.S. Pat. No. 5,433,912; Kaneishi, Kiboshi, Mio, and Fukui,
`U.S. Pat. No. 5,433,912; Kaneishi, Kiboshi, Mio, and Fukui,
`“Mold apparatus and injection molding method for produc
`"Mold apparatus and injection molding method for produc(cid:173)
`ing hollow-structured article by injection molding,” U.S.
`ing hollow-structured article by injection molding," U.S.
`35
`Pat. No. 5,656,234; and Foltuz; and Cohan, “Modular mold
`Pat. No. 5,656,234; and Foltuz; and Cohan, "Modular mold 35
`for injection molding and method of use thereof.” U.S. Pat.
`for injection molding and method of use thereof," U.S. Pat.
`No. 5,595,771, for the production of otherwise difficult
`No. 5,595,771, for the production of otherwise difficult
`geometry’s of injection molded parts. These tooling solu
`geometry's of injection molded parts. These tooling solu(cid:173)
`tions allow for the molding of some geometries, but there are
`tions allow for the molding of some geometries, but there are
`40
`limitations to the complexity of parts possible, and the cost
`limitations to the complexity of parts possible, and the cost 40
`of such tools may be prohibitive.
`of such tools may be prohibitive.
`The known art is also replete with examples of the use of
`The known art is also replete with examples of the use of
`expendable patterns in the forming of complex shapes. The
`expendable patterns in the forming of complex shapes. The
`casting industry commonly uses “lost wax,” and “lost foam”
`casting industry commonly uses "lost wax," and "lost foam"
`processes. In these processes, a mold is formed around a
`processes. In these processes, a mold is formed around a
`shaped material of wax, injection molded plastic, or poly
`shaped material of wax, injection molded plastic, or poly(cid:173)
`meric foam. It is the purpose of this material to form the
`meric foam. It is the purpose of this material to form the
`cavity and be vaporized upon casting of the molten metal.
`cavity and be vaporized upon casting of the molten metal.
`See, e.g., U.S. Pat. No. 5,906,234.
`See, e.g., U.S. Pat. No. 5,906,234.
`U.S. Pat. Nos. 5,614,232 & 5,242,646 to Torigoe et al.
`U.S. Pat. Nos. 5,614,232 & 5,242,646 to Torigoe et al.
`describe methods for making fasteners by injection molding
`describe methods for making fasteners by injection molding
`in which a sacrificial stem mold is used for defining exterior
`in which a sacrificial stem mold is used for defining exterior
`contours. U.S. Pat. No. 5,824,250 to Whalen et al. describes
`contours. U.S. Pat. No. 5,824,250 to Whalen et al. describes
`gel cast ceramic manufacturing using a fugitive mold. U.S.
`gel cast ceramic manufacturing using a fugitive mold. U.S.
`Pat. Nos. 5,248,552 & 5,089,186 to Moore et al. describe a
`Pat. Nos. 5,248,552 & 5,089,186 to Moore et al. describe a
`method for removing a core from a cast molded product,
`method for removing a core from a cast molded product,
`which is an inert particulate material with a water soluble
`which is an inert particulate material with a water soluble
`carbohydrate binder. U.S. Pat. No. 5,681,518 to Ashcraft
`carbohydrate binder. U.S. Pat. No. 5,681,518 to Ashcraft
`describes an injection molding process in which a plurality
`describes an injection molding process in which a plurality 60
`60
`of different mold components (including core components)
`of different mold components (including core components)
`of defined contour are formed and combined.
`of defined contour are formed and combined.
`U.S. Pat. No. 5,176,866 to Tanka and U.S. Pat. No.
`U.S. Pat. No. 5,176,866 to Tanka and U.S. Pat. No.
`5,173,237 to Kidd describe molding cores that use low
`5,173,237 to Kidd describe molding cores that use low
`melting point alloys which may be removed from a molded
`melting point alloys which may be removed from a molded
`article by heat, such as hot oil. U.S. Pat. No. 4,614,627 to
`article by heat, such as hot oil. U.S. Pat. No. 4,614,627 to
`Curtis et al. describes a method for molding a golf club head
`Curtis et al. describes a method for molding a golf club head
`
`Am. Honda v. IV II - IPR2018-00440
`PET_HONDA_1007-0004
`
`

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`5
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`3
`3
`According to yet another aspect of the invention, there has
`According to yet another aspect of the invention, there has
`been provided a method for producing an object comprising,
`been provided a method for producing an object comprising,
`multi-shot injection molding the object which injection
`multi-shot injection molding the object which injection
`molding includes: providing a support base containing a
`molding includes: providing a support base containing a
`tool; injecting a first material into the support base to form
`tool; injecting a first material into the support base to form
`an integral tool and sacrificial insert; separating the tool
`an integral tool and sacrificial insert; separating the tool
`from the sacrificial insert; retaining the sacrificial insert in
`from the sacrificial insert; retaining the sacrificial insert in
`the support base, or inserting the sacrificial insert into
`the support base, or inserting the sacrificial insert into
`another support base optionally having a further sacrificial
`another support base optionally having a further sacrificial
`insert or tool; injecting a second material into the support
`insert or tool; injecting a second material into the support 10
`10
`base containing the sacrificial insert to form an integral
`base containing the sacrificial insert to form an integral
`sacrificial insert and molded object; destructively disengag
`sacrificial insert and molded object; destructively disengag(cid:173)
`ing the sacrificial insert from the molded object without
`ing the sacrificial insert from the molded object without
`substantially damaging the molded object.
`substantially damaging the molded object.
`According to a further aspect of the invention, there has
`According to a further aspect of the invention, there has
`been provided a method for forming a molded ceramic
`been provided a method for forming a molded ceramic
`object, which includes: providing a mold having a sacrificial
`object, which includes: providing a mold having a sacrificial
`insert; providing a ceramic injection molding feedstock;
`insert; providing a ceramic injection molding feedstock;
`flowing the ceramic feedstock into the mold and into contact
`flowing the ceramic feedstock into the mold and into contact
`with the sacrificial insert; solidifying the ceramic material in
`with the sacrificial insert; solidifying the ceramic material in
`the mold to form an integral green molded ceramic object
`the mold to form an integral green molded ceramic object
`and sacrificial insert; and subjecting the integral green
`and sacrificial insert; and subjecting the integral green
`molded ceramic object and sacrificial insert to a treatment
`molded ceramic object and sacrificial insert to a treatment
`sufficient to destroy the sacrificial insert, whereby the sac
`sufficient to destroy the sacrificial insert, whereby the sac(cid:173)
`rificial insert can be separated from the molded ceramic
`25
`rificial insert can be separated from the molded ceramic 25
`object without substantially damaging the molded object.
`object without substantially damaging the molded object.
`According to a further aspect of the invention, there has
`According to a further aspect of the invention, there has
`been provided a method for forming a molded metal object,
`been provided a method for forming a molded metal object,
`which includes: providing a mold having a sacrificial insert;
`which includes: providing a mold having a sacrificial insert;
`providing a metal injection molding feedstock; flowing the
`providing a metal injection molding feedstock; flowing the
`metal feedstock into the mold and into contact with the
`metal feedstock into the mold and into contact with the
`sacrificial insert; solidifying the metal material in the mold
`sacrificial insert; solidifying the metal material in the mold
`to form an integral green molded metal object and sacrificial
`to form an integral green molded metal object and sacrificial
`insert; and subjecting the integral green molded metal object
`insert; and subjecting the integral green molded metal object
`and sacrificial insert to a treatment sufficient to destroy the
`and sacrificial insert to a treatment sufficient to destroy the
`sacrificial insert, whereby the sacrificial insert can be sepa
`sacrificial insert, whereby the sacrificial insert can be sepa(cid:173)
`rated from the molded metal object without substantially
`rated from the molded metal object without substantially
`damaging the molded object.
`damaging the molded object.
`Further objects, features and advantages of the present
`Further objects, features and advantages of the present
`invention, will become readily apparent from detailed con
`invention, will become readily apparent from detailed con(cid:173)
`sideration of the preferred embodiments which follow.
`sideration of the preferred embodiments which follow.
`DESCRIPTION OF THE DRAWINGS
`DESCRIPTION OF THE DRAWINGS
`FIG. 1 depicts various sacrificial inserts according to one
`FIG. 1 depicts various sacrificial inserts according to one
`embodiment of the invention.
`embodiment of the invention.
`FIG. 2 depicts an integral molded object/sacrificial insert/
`FIG. 2 depicts an integral molded object/sacrificial insert/
`tool.
`tool.
`FIG.3 depicts the molded object after the sacrificial insert
`FIG. 3 depicts the molded object after the sacrificial insert
`50
`has been destructively removed and the tool has been
`has been destructively removed and the tool has been 50
`removed.
`removed.
`
`DETAILED DESCRIPTION OF THE
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`PREFERRED EMBODIMENTS
`The present invention provides a method for injection
`The present invention provides a method for injection
`molding objects, such as parts, with complex geometries.
`molding objects, such as parts, with complex geometries.
`This method allows complex features, particularly interior
`This method allows complex features, particularly interior
`features, to be added to the object by insert molding with a
`features, to be added to the object by insert molding with a
`sacrificial insert. Injection molding using conventional
`sacrificial insert. Injection molding using conventional
`molds is well known, as described in “Injection Molding
`molds is well known, as described in "Injection Molding
`Handbook” by D. V. Rosato et al. (Chapman & Hall
`Handbook" by D. V. Rosato et al. (Chapman & Hall
`Publishing, 2" edition, 1995) which is incorporated by
`Publishing, 2nd edition, 1995) which is incorporated by
`reference in its entirety.
`reference in its entirety.
`The sacrificial insert is prepared from a material that will
`The sacrificial insert is prepared from a material that will
`be removed in a later step. By using the present invention,
`be removed in a later step. By using the present invention,
`the complexity of tooling may be reduced, and features
`the complexity of tooling may be reduced, and features
`
`US 6,547,210 Bl
`US 6,547,210 B1
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`4
`previ