(12) Patent Application Publication (10) Pub. No.: US 2004/ A1

Transcription

1 US A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2004/ A1 Gallops, JR. (43) Pub. Date: Apr. 1, 2004 (54) METHOD FOR MANUFACTURING (21) Appl. No.: 10/ ARCHERY BOW RISERS AND THE ARCHERY BOWS INCLUDING THE RISERS (22) Filed: Sep. 26, 2002 PRODUCED BY THE METHOD Publication Classification (76) Inventor: Henry M. Gallops JR., Gainesville, FL (US) (51) Int. Cl."... F41B 5/00 (52) U.S. Cl /23.1 Correspondence Address: WOODARD, EMHARDT, MORIARTY, (57) ABSTRACT MCNETT & HENRY LLP BANK ONE CENTER/TOWER A method for manufacturing an archery bow riser of hollow 111 MONUMENT CIRCLE, SUITE 3700 construction by the tubular hydroforming process and the INDIANAPOLIS, IN (US) risers produced by the method.

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8 US 2004/ A1 Apr. 1, 2004 METHOD FOR MANUFACTURING ARCHERY BOW RISERS AND THE ARCHERY BOWS INCLUDING THE RISERS PRODUCED BY THE METHOD CROSS-REFERENCE TO RELATED APPLICATIONS There are no related applications. STATEMENTS AS TO RIGHTS TO INVENTION MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 0002 The invention disclosed and claimed herein was not made under any federally sponsored research and devel opment program. A. BACKGROUND OF THE INVENTION 0003) 1. Field of the Invention This invention concerns a method for manufactur ing archery bow risers and the archery bows including Such risers produced by the method Description of the Prior Art 0006 Archery bow risers, particular archery bow risers for use with compound bows, are required to be Strong enough to withstand the large forces produced by the limbs during firing of the bow. In the past, risers possessing Such Strength have been manufactured by various processes including the milling of aluminum blocks or billets, the casting of magnesium and aluminum in molds and the extruding of aluminum. A disadvantage of these processes is that the risers So produced are heavy and contribute signifi cantly to the weight of the bow. Users of such bows, for example hunters in the fields, would prefer that the bows be lighter in weight The production of shaped parts by a process referred to as tube hydroforming has become popular in recent times, particularly for parts used in the automotive industry. The process involves placing either a Straight metal tube, or a metal tube prebent into the general overall shape of the part to be formed, into a hydraulically activated die. The die cavity is in the shape of the part to be formed. The die parts are then closed and pressurized water is forced into the ends of the tube causing the tube to expand outwardly into the shape of the die cavities. The principal benefit of tube hydroforming is the Significant weight Saving that is achieved by a hollow component. Other reported benefits of tube hydroforming include part consolidation (i.e., the advantage of using a one piece hollow tube instead of Stamping and welding two or more pieces); weight reduction through enhanced control of wall thickness, lower tooling costs, reduced dimensional variations and reduced amount of Scrap material. Adding to the popularity of tube hydro forming in recent times has been the advanced Software programming which allows more finely tuned movement of the dies and the resultant production of parts to exacting specifications. It is not believed that the tube hydroforming process has been previously utilized to produce archery bow SCS. B. SUMMARY OF THE INVENTION The present invention is directed to a method for manufacturing an archery bow riser of hollow construction by the tubular hydroforming process and the archery bow risers produced by that method. It is believed that such a hollow construction riser will be able to withstand the Significant forces produced by the limbs because most of the riser strength which withstands the limb forces is at the outer edges of the riser and therefore any riser Strength lost by the hollow interior construction is not critical The process for manufacturing an archery bow of hollow construction involves prebending a hollow metal tube into the general overall shape of the riser. The riser shape may, for example, include grip attachment Surfaces, a bow Sight mounting Surface, and limb attachment areas. The bent tube is then placed into a cavity in a lower hydraulically activated die. The cavity is in the shape of a first Surface of the riser to be formed and includes, for example, the shape of the grip area, arrow shelf and/or bow Sight mounting Surface. An upper hydraulically activated die includes a cavity in the shape of a Second Surface of the riser to be formed. The upper and lower dies are closed about the bent tube and water under pressure is forced into the ends of the tube. The combination of the closure of the dies and the internal water pressure in the tube deforms the bent tube into the shape of the cavities in the dies. The dies are then Separated and the riser is removed Accordingly, it is an object of this invention to form a light weight archery bow riser by means of a hydroforming process, It is a further object of this invention to form a light weight archery bow riser including grip attachment Surfaces by means of a hydroforming process, It is an additional object of this invention to form a light weight archery bow riser including a bow Sight mounting Surface by means of a hydroforming process, It is a still further object of this invention to form a light weight archery bow riser including limb attachment areas by means of a hydroforming process, and It is another object of this invention to form a light weight archery bow riser including a grip portion, an arrow Shelf and a bow Sight mounting Surface by means of a hydroforming process Other objects and attendant advantages of this invention will be readily appreciated as the same becomes more clearly understood by references to the following detailed description when considered in connection with the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof. C. BRIEF DESCRIPTION OF THE DRAWINGS 0016 FIG. 1 is a side elevational view of an archery bow including the riser produced according to the present inven tion; 0017 FIG. 1A is a front elevational view of the archery bow shown in FIG. 1; 0018 FIG. 2 is a perspective view of the tubular extru sion from which the riser of the present invention is formed; 0019 FIG. 3 is a side view of the tubular extrusion shown in FIG. 2;

9 US 2004/ A1 Apr. 1, FIG. 4 is a top plan view of the tubular extrusion shown in FIG. 2; 0021 FIG. 5 is a side to side view of the prebent tubular extrusion; 0022 FIG. 6 is a front to back view of the prebent tubular extrusion; 0023 FIG. 7 is a top plan view of the prebent tubular extrusion; 0024 FIG. 8 is a perspective view of the opened dies and the prebent tubular extrusion placed in a cavity of the lower die, 0025 FIG. 9 is a perspective view of the closed dies and the prebent tubular extension located in the cavities of the upper and lower die; FIG. 10 is a perspective view of the opened dies and the formed riser removed from the dies; and 0027 FIG. 11 is a perspective view of the formed riser after the ends of the limb attachment areas have been further shaped to receive the limb attachment devices. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompa nying drawing forming a part of this specification and in which Similar numerals of reference indicate corresponding parts in all the figures of the drawing In FIG. 1 there is shown an archery bow 2 includ ing a riser 4 of the type produced in accordance with the present invention. Riser 4 includes grip attachment Surfaces 6 to which grip 7 having an arrow shelf 8 thereon is secured by, for example, Screws or adhesive. Riser 4 includes a bow sight mounting surface 10 and limb attachment areas 9 having angular Surfaces 13 at the ends of riser 4. Riser 4 is connected at one end to an upper limb 12 by a conventional limb attachment device 11 and at the other end by conven tional limb attachment device 11 to a lower limb 14. The riser 4 is connected to the limb attachment devices 11 by bolts 17. A dual feed cam 15 is mounted on an axle pin which extends through the bottom of lower limb 14. A concentric pulley wheel 16 is mounted on an axial pin which extends through the top of upper limb ) A string has a medial portion trained around pulley wheel 16 to form bow string 18 and a secondary return string 20. The ends of bowstring 18 and secondary return string 20 pass around eccentric peripheral groove portions of the cam 15 and are connected to it, so that when the bow is fired, bow string 18 and return string 20 will be fed out from cam 15. An anchor cable 22 is anchored at one end to the axle which extends through the top of upper limb 12. The other end of anchor cable 22 passes around an eccentric peripheral groove portion of cam 15 and is connected to it. In this manner, anchor cable 22 forms a direct connection between the limbs 12 and 14. While the illustrated bow is a dual-feed Single-cam compound bow of the type disclosed in U.S. Pat. No. 5,368,006, it will be understood that the riser produced in accordance with the present invention may be used with other types of bows as well The process for producing riser 4 begins with a tubular extrusion 24 of the type shown in FIGS. 2 through 4. Tubular extrusion 24 which may, for example, be formed of aluminum or Steel, includes a hollow interior 26 and openings 23 and 25. Tubular extrusion 24 may, for example, have a wall thickness of inches, a height of 0.75 inches and a width of 1.5 inches. The tubular extrusion 24 is then prebent manually to the shape shown in FIGS. 5 through 7 so that it may fit within a cavity 19 of bottom die 28 shown in FIG.8. The cavity 19 is in the shape of a first surface of the riser to be formed and includes the area of tubular extrusion 24 which will be formed into the grip attachment Surfaces 6 and is shown generally as 6', the area of tubular extrusion 24 which will be formed into the bow sight mounting Surface 10 and is shown generally as 10, and the area of tubular extrusion 24 which will be formed into the limb attachment areas 9 is shown generally at 9" in FIGS. 5 and ). In FIG. 8, the tubular extrusion 24 is shown in a cavity 19 in bottom die 28 prior to an upper die 30 and bottom die 28 being brought together and the internal fluid being injected under pressure into both ends of the tubular extrusion 24. Either upper die 30 may be moved down wardly into contact with lower die 28 or lower die 28 may be moved upwardly into contact with upper die 30. Upper die 30 includes a corresponding cavity 21 in the shape of a second surface of the riser to be formed. The next step is shown in FIG. 9 wherein upper die 30 and lower die 28 are brought into contact and internal fluid is injected into openings 23 and 25 of tubular extrusion 24 in the direction of the arrows. The pressure exerted by die 28 on tubular extrusion 24 may, for example, be in the range of 40,000 to 60,000 pounds per square inch and the pressure of the internal fluid injected into tubular extrusion 24 may be in the range of 20,000 to 30,000 pounds per square inch. During this step, the combination of the upper die 30 and the bottom die 28 being closed on tube extrusion 24 and the internal fluid being injected into openings 23 and 25 of tube extru Sion 24 forces the external Surfaces of tube extrusion 24 to conform to the surface of cavity 19 in bottom die 28 and cavity 21 in upper die 28. In the next step shown in FIG. 10, the bottom die 28 and the upper die 30 of die 28 are Separated and the riser 4 is removed. The angular Surfaces 13 of limb attachment areas 9 are then further shaped by, for example, machining or cold Sawing to enable the angular Surfaces 13 to receive the limb attachment devices. A perspective view of the finished riser 4 is shown in FIG This invention has been described above with reference to presently preferred embodiments of the inven tion; Such description has not been presented as a catalog exhaustive of all forms which this invention may take. Accordingly, workers skilled in the art to which this inven tion pertains will readily appreciate that variations, alter ations or modifications in the Structures, procedures and arrangements described above may be practiced without departing from the Scope of this invention. Thus, the fore going description should not be read as limiting the Scope of this invention to less than the fair Scope of the appended claims. What is claimed as novel and desired to be secured by Letters Patent is: 1. An archery bow having a riser and a pair of limbs attached to Said riser, characterized in that Said riser is made

10 US 2004/ A1 Apr. 1, 2004 from a tubular member which is formed into the shape of the riser by a hydroforming process. 2. An archery bow as recited in claim 1 wherein the tubular member is a tubular extrusion. 3. An archery bow as recited in claim 1 wherein the tubular member is prebent prior to being formed into the shape of the riser by the hydroforming process. 4. An archery bow as recited in claim 1 wherein the riser includes grip attachment Surfaces. 5. An archery bow as recited in claim 1 wherein the riser includes a bow Sight mounting Surface. 6. An archery bow as recited in claim 1 wherein the riser includes limb attachment areas. 7. A riser for use in an archery bow characterized in that said riser is made from a tubular member which is formed into the shape of the riser by a hydroforming process. 8. A riser as recited in claim 7 wherein the tubular member is a tubular extrusion. 9. A riser as recited in claim 7 wherein the tubular member is prebent prior to being formed into the shape of the riser by the hydroforming process. 10. A riser as recited in claim 7 wherein the riser includes grip attachment Surfaces. 11. A riser as recited in claim 7 wherein the riser includes a bow Sight mounting Surface. 12. A riser as recited in claim 7 wherein the riser includes limb attachment areas. 13. A method of manufacturing an archery bow riser of tubular construction by the hydroforming process, Said method including the Steps of a) forming a cavity in a bottom die, said cavity being in the shape of a first Surface of the riser to be manufac tured; b) placing a tubular member in the cavity of the bottom die, c) forming a cavity in an upper die, said cavity being in the shape of a Second Surface of the riser to be manu factured; d) bringing said upper die and bottom die together while injecting fluid under pressure into Said tubular member to form Said riser; and e) separating Said upper die and bottom die and removing Said riser. 14. A method of manufacturing an archery bow riser as recited in claim 13 and including the further Step of Shaping the ends of the riser after step e) to enable the ends of the riser to receive the limb attachment devices. 15. A method of manufacturing an archery bow riser as recited in claim 13 wherein the fluid is injected under pressure into opposite openings of Said tubular member. 16. A method of manufacturing an archery bow riser as recited in claim 13 wherein the tubular member is prebent before it is placed in the cavity in the bottom die. 17. A method of manufacturing an archery bow riser as recited in claim 13 wherein said tubular member is a tubular extrusion.