SYNTHETIC METAL SYSTEM

Abstract

A synthetic metal system comprising a frame member comprising a cellular structure including a plurality of openings; and a matrix material comprising a polymeric material, wherein the matrix material is configured to at least partially penetrate one or more of the plurality of openings in the frame member such that the frame member is at least partially encased within the matrix material.

Claims

1. A synthetic metal system comprising: a frame member comprising a cellular structure including a plurality of openings; and a matrix material comprising a polymeric material, wherein the matrix material is configured to at least partially penetrate one or more of the plurality of openings in the frame member such that the frame member is at least partially encased within the matrix material.

2. The_synthetic metal system according to claim 1 wherein the plurality of openings is defined by a plurality of frame elements which form the frame member.

3. The synthetic metal system according to claim 1 wherein the frame member is a lattice structure.

4. The synthetic metal system according to claims 1 wherein the plurality of openings defines a cavity within and/or on a surface of the frame member.

5. The synthetic metal system according to claim 1 wherein the frame member comprises two or more portions and wherein the frame member portions are configured for connection to one another and/or are retained in place relative to one another within the synthetic metal system by the matrix material.

6. The synthetic metal system according to claim 1, wherein at least a portion of the frame member is in at least partial contact with the environment external to the synthetic metal system.

7. The synthetic metal system according to claim 1, wherein at least a portion of the frame member is fabricated from a metallic material.

8. The synthetic metal system according to claim 1, wherein at least a portion of the frame member is fabricated from an electrically conductive material and/or a thermally conductive material.

9. The synthetic metal system according to claims 1, wherein at least a portion of the frame member is fabricated from a resiliently deformable material.

10. The synthetic metal system according to claim 1, wherein the matrix material comprises one or more thermoplastic, thermosetting and/or elastomeric polymeric materials.

11. The synthetic metal system according to claim 1, wherein the matrix material comprises a polymeric material suitable for processing by injection moulding and/or extrusion.

12. The synthetic metal system according to claims 1, wherein the matrix material comprises a multi-phase chemo-synthetic copolymer thermoplastic polyurethane matrix.

13. The synthetic metal system according to claims 1, wherein the matrix material further comprises a carbon fiber.

14. The synthetic metal system according to claim 1, further comprising a unique identifier.

15. The synthetic metal system according to claims 1, wherein the synthetic metal system is used to fabricate a component of a bottom hole assembly.

16. The synthetic metal system according to claim 15, wherein the synthetic metal system provides cathodic protection to the bottom hole assembly.

17. The synthetic metal system according to claim 1, wherein the synthetic metal system is used to fabricate a core and/or a mantle layer of a ball.

18. The synthetic metal system according to claim 17, wherein the synthetic metal system is resiliency deformable.

19. The synthetic metal system according to claim 1 wherein the synthetic metal system is used to fabricate a projectile.

20. The synthetic metal system according to claims 1 wherein the synthetic metal system used to fabricate a component for use in a medical application and/or a dental application.

21. The synthetic metal system according to claim 20, wherein the synthetic metal system is used to fabricate a prosthetic device and/or an implant.

22. The synthetic metal system according to claim 1 wherein the synthetic metal system is used to fabricate a component for use in space or other thermo-vacuum cyclic environments.

23. A method of manufacturing a synthetic metal system, including the steps of: a. Placing a frame member comprising a cellular structure including a plurality of openings into a mould cavity; b. Injecting a matrix material comprising a polymeric material into the mould cavity, wherein the matrix material is configured to at least partially penetrate one or more of the plurality of openings in the frame member such that the frame member is at least partially encased within the matrix material; c. Cooling the mould cavity together with the moulded synthetic metal system until the moulded matrix material is cooled below the glass transition temperature of the matrix material; and d. Ejecting the synthetic metal system from the mould cavity.

24. The method of manufacturing a synthetic metal system according to claim 23 wherein the frame member comprises two or more frame member portions and wherein the step of placing the frame member into the mould cavity comprises connecting the respective frame member portions to one another to form the frame member before placing the frame member into the mould cavity.

25. The method of manufacturing a synthetic metal system according to claim 24 wherein the frame member comprises two or more frame member portions and wherein the step of placing the frame member into the mould cavity comprises placing the two or more frame member portions into the mould cavity.

26. The method of manufacturing a synthetic metal system according to claim 23 further comprising the step of placing at least a portion of an elongate member in the mould cavity, wherein the frame member at least partially encases the elongate member.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0099] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0100] FIG. 1 illustrates a side view of a frame member according to an embodiment of the present invention.

[0101] FIG. 2 illustrates a side view of a synthetic metal system according to an embodiment of the present invention.

[0102] FIG. 3 illustrates a side view of a synthetic metal system in the form of a rod guide connected to a sucker rod according to an embodiment of the invention.

[0103] FIG. 4 illustrates a perspective view of a synthetic metal system in the form of a combustion engine piston according to an embodiment of the invention.

[0104] FIG. 5 illustrates a partial cutaway view of a golf ball comprising a synthetic metal system core according to an embodiment of the invention.

[0105] FIGS. 6A-6D illustrate various frame members for use in a core of a ball according to an embodiment of the present invention.

[0106] FIGS. 7A and 7B illustrate various frame members for use in fabricating a synthetic metal system projectile according to an embodiment of the invention.

[0107] FIGS. 8A and 8B illustrate a frame member for use in fabricating a synthetic metal system projectile in an unassembled state according to an embodiment of the invention.

[0108] FIG. 9 illustrates a frame member for use in fabricating a synthetic metal system projectile in an assembled state according to an embodiment of the invention.

[0109] FIG. 10 illustrates a synthetic metal system projectile according to an embodiment of the invention.

DESCRIPTION OF EMBODIMENTS

[0110] FIG. 1 illustrates a side view of a frame member 10 according to an embodiment of the present invention. In this Figure, frame member 10 comprises two portions 12,14 configured for connection to one another by male-female connection portions 26,28. Frame member 10 comprises a relatively rigid cellular structure comprising a plurality of openings 22 fabricated by three-dimensional printing of a metallic material, wherein the plurality of openings 22 is defined by a lattice of bars 24 laid down during fabrication of the frame member 10.

[0111] Frame member 10 is provided with a recessed portion 20 extending from a first end 16 to a second end 18 of the frame member 10, wherein the recessed portion 20 is configured to receive at least a portion of an elongate member (not shown) therein, wherein, when the frame member portions 12,14 of the frame member 10 are connected to one another, it is envisaged that the frame member 10 at least partially encases the elongate member (not shown). The frame member 10 is substantially the same size, shape and configuration of a synthetic metal system suitable for replacing a component in a rod string.

[0112] FIG. 2 illustrates a side view of a synthetic metal system 50 according to an embodiment of the present invention. In this Figure, the synthetic metal system 50 comprises a frame member 52 comprising a cellular structure including a plurality of openings and a matrix material 58, wherein the matrix material 58 is configured to at least partially penetrate one or more of the plurality of openings 54 in the frame member 52 such that the frame member 52 is at least partially encased within the matrix material 58.

[0113] In use it is envisaged that synthetic metal system 50 may be formed by placing a frame member 52 into a mould cavity (not shown), injecting a matrix material 58 into the mould cavity, wherein the matrix material 58 is configured to at least partially penetrate openings 54 in the frame member 52 such that the frame member 52 is at least partially encased within the matrix material 58, cooling the mould cavity together with the moulded synthetic metal system 50 until the moulded matrix material 58 is cooled below its glass transition temperature and ejecting the moulded synthetic metal system 50 from the mould cavity.

[0114] FIG. 3 illustrates a side view of a synthetic metal system 100 in the form of a rod guide 102 connected to a portion of a sucker rod 104 according to an embodiment of the invention. In this Figure, the synthetic metal system 100 may be overmoulded to at least a portion of the sucker rod 104 such that the synthetic metal system 100 may be integrally moulded to at least a portion of the sucker rod 104. Preferably, synthetic metal system 100 comprises a frame member fabricated from an electrically conductive metallic material and a matrix material comprising a polymeric material having low-friction (self-lubricating) and high abrasion resistance.

[0115] In use, it is envisaged that the synthetic metal system 100 may replace a rod guide of a rod string, such that the synthetic metal system may replace and function as a rod guide without affecting the operation of a sucker rod pump system comprising the rod string. In use, it is envisaged at least a portion of the frame member may be exposed to the environment through the matrix material, thereby acting as a conduit of electrons and providing cathodic protection to the sucker rod pump system. Similarly, the synthetic metal system may act as a conduit of electrons and provide cathodic protection to any well bore or component thereof, such as a well casing, a portion of a pipeline, a bottom hole assembly, a portion of a production tubing string, a portion of a drill string, or the like.

[0116] FIG. 4 illustrates a perspective view of a synthetic metal system 150 in the form of a combustion engine piston. In this Figure, the synthetic metal system 150 may comprise an injection moulded ceramic matrix material comprising a steel or steel alloy frame member. In this instance, it is envisaged that the frame member may reduce the brittleness of the ceramic matrix material and may assist in conducting heat away from an outer surface of the combustion engine piston. In this instance, it is envisaged that the frame member may comprise one or more hollow frame elements comprising a coolant or may comprise one or more projections extending out of the matrix material such that heat is removed from the synthetic metal system by convection.

[0117] FIG. 5 illustrates a partial cutaway view of a golf ball 200 comprising a synthetic metal system core 202. In this Figure, the synthetic metal system core 202 comprises a frame member 204 and a matrix material 206, wherein the matrix material 206 is configured to at least partially penetrate openings 208 in frame member 204 such that the frame member 204 is at least partially encased within the matrix material 206. Matrix material 206 may be a rubber such as neodymium-catalysed polybutadiene rubber (Nd-BR), a copolymer blend such as ARPMAX®, or the like. Synthetic metal system core 202 of golf ball 200 is provided with an intermediate layer 210 (such as rubber), and an outer cover layer 212 (such as SURLYN® ionomer resin or a polyurethane/acetal blend). In use, it is envisaged that a golf ball comprising a resiliently deformable synthetic metal system core may improve the coefficient of restitution and increasing the moment of inertia, thereby reducing side spin and providing a more stable and predictable flight.

[0118] FIGS. 6A-6D illustrate various frame members for use in a synthetic metal system core for a ball. FIGS. 6A and 6B illustrate frame members having a cellular structure wherein the plurality of openings is formed from a Voronoi pattern. FIG. 6C illustrates a frame member having a cellular structure wherein the plurality of openings is triangle-based. FIG. 6D illustrates a frame member having a cellular structure wherein the plurality of openings is a lattice structure comprising a network of nodes and frame elements based on a triangle microstructure.

[0119] FIGS. 7A and 7B illustrate various frame members for use in fabricating a synthetic metal system projectile. Frame members 220,240 comprises a three-dimensional printed metal alloy lattice structure comprising a plurality of openings 222,242 defined by a plurality of frame elements 224,244. In FIG. 7A, frame member 240 comprises a truncated cone-shaped tip portion 246, wherein the tip of the synthetic metal system projectile may be formed substantially entirely from the matrix material (not shown) during the injection moulding process. The synthetic metal may also form part of the external shell (exoskeleton) which is connected to the endoskeleton lattice at the concave base and/or at the projectile tip. In FIG. 7B, frame member 220 is substantially the same size, shape, and configuration as the synthetic metal system projectile. In FIGS. 5A and 5B, frame member 220,240 may be provided with a base 228,248 having a concave profile configured to direct the explosive energy into the centre of the base of the projectile.

[0120] FIGS. 8A-8B, 9 and 10 illustrate a synthetic metal system projectile 300 comprising a frame member fabricated from two portions 302,304. In FIGS. 8A and 8B, a frame member 300 fabricated from two portions 302,304 in a dissembled state is illustrated. Frame member portions 302,304 are configured for connection to one another via complementary elongated slots 306,308 located in a region of each of the frame member portions 302,304. Each frame member portion comprises a plurality of openings 310. In FIG. 9, the frame member 300 is fabricated from two portions 302,304 is illustrated in an assembled state. In FIG. 10, a synthetic metal system comprising a frame member 300 is overmoulded with a matrix material 312, wherein the matrix material is configured to at least partially penetrate openings 310 in the frame member 300 such that the frame member 300 is at least partially encased with the matrix material 312.

[0121] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0122] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0123] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.