# US 2019/0168307 A1 · Method for manufacturing metal products of irregular shape > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168307 A1 - Document ID: US20190168307A1 - Status: Published application - Kind: A1 - Application number: 15/859,764 - Filed: 2018-01-02 - Published: 2019-06-06 - Earliest claimed: 2017-12-06 - Assignees: Champ Tech Optical (Foshan) Corporation - Applicants: Champ Tech Optical (Foshan) Corporation - Inventors: DUNG-CHANG YEH; YI-FAN LIN; JIN-HONG ZHU - Web page: https://patentgrep.com/patent/US20190168307A1 ## CPC - B22F 3/225: {by injection molding} - B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups - B22F 5/106: {Tube or ring forms} - B22F 7/062: {involving the connection or repairing of preformed parts} - B22F 2998/10: Processes characterised by the sequence of their steps - B23K 20/10: making use of vibrations, e.g. ultrasonic welding - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM ## Abstract A method for manufacturing hollow and other metal products of irregular shape provides metal powder and binding agent, and the two are feed-mixed and heated to a plastic state. The feed-mix is injected in a mold cavity of a first injection mold to form a first blank, and injected in a mold cavity of a second injection mold to form a second blank. The first blank and the second blank are welded together to form a built-up blank which is degreased to remove the binding agent therein. The degreased built-up blank is sintered to obtain the metal product of irregular shape. ## Claims ### Claim 1 A method for manufacturing metal product of irregular shape comprising: providing powder and binding agent, and mixing the powder and binding agent as a feed; heating the feed to a plastified state, and injecting the feed in a mold cavity of a first injection mold to form a first blank, and injecting the feed in a mold cavity of a second injection mold to form a second blank; welding the first blank and the second blank together to form a built-up blank; degreasing the built-up blank to remove the binding agent therein; and sintering the degreased built-up blank and obtaining the metal product of irregular shape. ### Claim 2 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein the sintering temperature is 1100-1350° C., the sintering time is 0.5-5 hours, and the cooling rate is 3-30° C./minute. ### Claim 3 (depends on 2) The method for manufacturing metal product of irregular shape of claim 2, wherein after the step of sintering, further comprising a step of a low temperature and heat treatment process, the tempering temperature is 150-400° C. and the tempering time is 0.5 to 5 hours. ### Claim 4 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein the welding method comprises ultrasonic welding, friction pressure welding, or heating and pressure welding. ### Claim 5 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein the powder is selected from metal powder, ceramic powder, or pre-alloyed powder. ### Claim 6 (depends on 4) The method for manufacturing metal product of irregular shape of claim 4, wherein a structure of the first blank is same to a structure of the second blank. ### Claim 7 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein a structure of the first blank is different from a structure of the second blank. ### Claim 8 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein the metal product of irregular shapes refer to a metal product which cannot direct obtained via a method of injection molding, demoulding and sintering. ### Claim 9 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein the first blank and the second blank are bonded at edges thereon and together form a hollow cavity. ### Claim 10 (depends on 9) The method for manufacturing metal product of irregular shape of claim 9, wherein the hollow cavity can be a sealing cavity or an unsealed cavity. ### Claim 11 (depends on 9) The method for manufacturing metal product of irregular shape of claim 9, wherein the first blank comprises a first mating surface and a first cavity surrounded by the first mating surface; the second blank comprises a second mating surface and a second cavity surrounded by the second mating surface, the first mating surface is welded with the second mating surface, and the first cavity and the second cavity together form the hollow cavity. ### Claim 12 (depends on 11) The method for manufacturing metal product of irregular shape of claim 11, wherein the first mating surface comprises a first matching portion, the second mating surface comprises a second matching portion corresponding to the first matching surface. ### Claim 13 (depends on 12) The method for manufacturing metal product of irregular shape of claim 12, wherein a cross section of the first matching portion is triangular, the second matching portion is a groove, and the first matching portion and the second matching portion are point contact, and the first blank is welded with the second blank via ultrasonic welding. ### Claim 14 (depends on 1) The method for manufacturing metal product of irregular shape of claim 1, wherein the first blank and the second blank are other than at the edges, and edges of the first blank and the second blank are spaced from each other. ### Claim 15 (depends on 14) The method for manufacturing metal product of irregular shape of claim 14, wherein the first blank comprises a base and a supporting pillar protruding from the base, and the pillar comprises a stepping portion, the second blank is an inverted fastener, the second blank comprises an inserting hole matching to the stepping portion, and the inserting hole.