Abstract: A mold includes a mold insert body made of at least two kinds of materials. The materials have different coefficients of thermal conductivity. The mold insert body includes a union part formed by sintering the materials, and the union part has a configuration set so as to correspond to a cooling way of a molding material flowed in a cavity forming part of the mold.

Abstract: The present invention provides methods and apparatus for selectively patterning surfaces using radical species generated with a photocatalyst. The photocatalyst may comprise a photocatalytic semiconductor or a photosensitizer. The radical species are brought into contact with an oxidizable coating disposed on the surface, thereby locally oxidizing and selectively patterning the surface. The photocatalyst is preferably disposed on a delivery device, such as a stamp, mask, or scanning probe, that is brought into close proximity or contact with the coated surface. The photocatalyst is then excited in a manner capable of generating radical species, for example, oxygen-containing radical species, in appropriate media. It is expected that these radical species will be transferred to the coated surface along a substantially shortest distance path, thereby locally oxidizing and patterning the surface.

Abstract: A method for preparing a mold form includes forming a mold blank having a surface corresponding to the surface of the article desired and enclosing the mold blank in an open ended enclosure. A thin layer of polymer resin, preferably polyurea is sprayed on the surface of the mold blank and allowed to cure. Heat transfer tubing is inserted over the resin layer. A mixture of metallic pellets and epoxy are inserted over the heat transfer tubing and then another layer of resin is sprayed over the mixture. After the resin has cured, the mold blank is removed to expose the mold form having an outer surface of polyurea.

Abstract: Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon.

Abstract: A film is provided on a mold used during semiconductor device fabrication through surface modifications to the mold to provide non-stick characteristics and a mold surface that is resistant to abrasion or wear. Such surface modifications are particularly useful in a mold having a quartz planar surface adapted to contact a photocurable polymer material applied to a semiconductor wafer surface during a fabrication process. The planar surface of the mold is capable of allowing transmission of ultraviolet light therethrough to cure the polymer material. A non-stick film is formed on the planar surface of the mold by a coating or deposition process in order to modify the mold surface. The non-stick film can be formed of a fluoroalkylsilane compound, or a hard material such as diamond or diamond-like carbon. The non-stick film of diamond or diamond-like carbon provides protection against abrasion or wear on the planar surface of the mold.

Abstract: An oxidation and corrosion resistant coating is applied to glass forming equipment by physical vapor deposition. The coating material is preferably aluminum oxide.

Abstract: This invention relates to the preparation of molds for the production of contact lenses and other ophthalmic articles. By using an inorganic material to coat the optical surfaces and sidewalls of mold parts made from clear-resin materials, manufacturers can produce lens molds with greater dimensional stability and chemical resistance. In addition to protecting the clear resin from interaction with otherwise reactive monomers from which the molded article is made, such coatings can also be used to achieve preferential release of the molded article. The resulting mold is especially useful for providing an economical way to improve manufacturing quality of contact lenses.

Abstract: An electromechanical device includes a first frame having a first aperture therein, a second frame suspended in the first frame wherein the second frame has a second aperture therein, and a plate suspended in the second aperture. A first pair of beams support the second frame along a first axis relative to the first frame so that the second frame rotates about the first axis. A second pair of beams supports the plate along a second axis relative to the second frame so that the plate rotates about the second axis relative to the frame. The first and second axes preferably intersect at a 90° angle. A first actuator provides mechanical force for rotating the second frame relative to the first frame about the first axis. A second actuator provides mechanical force for rotating the plate relative to the second frame about the second axis. Accordingly, the plate can be independently rotated relative to the first axis and the second axis. Related methods are also disclosed.

Abstract: A device for stamping a detergent bar, i.e. a bar comprising soap, a synthetic detergent active or a mixture thereof, includes a die. The die has at least one bar stamping surface provided with at least one elastomeric coating which includes a conductive filler such as stainless steel powder. Good release of the detergent bars from the die is possible particularly when the dies are chilled. Use of the conductive filler facilitates chilling of the dies.

Abstract: Surface modifications of a mold used during semiconductor device fabrication provide non-stick characteristics and a mold surface that is resistant to abrasion or wear. Such surface modifications are particularly useful in a mold having a quartz planar surface adapted to contact a photocurable polymer material applied to a semiconductor wafer surface during a fabrication process. The planar surface of the mold is capable of allowing transmission of ultraviolet light therethrough to cure the polymer material. A non-stick film is formed on the planar surface of the mold by a coating or deposition process in order to modify the mold surface. The non-stick film can be formed of a fluoroalkylsilane compound, or a hard material such as diamond or diamond-like carbon. The non-stick film of diamond or diamond-like carbon provides protection against abrasion or wear on the planar surface of the mold.

Abstract: Method comprises:

Abstract: A method for molding an optical disk includes applying a thermally insulative mold insert onto a thermally conductive mold form by coating the mold insert on the mold form. The mold insert has a coefficient of thermal expansion compatible with the coefficient of thermal expansion of the mold form and includes an adhesion promoting material. The method further includes positioning the coated mold form in a thermally conductive mold apparatus with the mold insert positioned between the mold form and the mold apparatus; injecting a molten thermoplastic material into the mold apparatus; retaining the molten thermoplastic material in the mold apparatus for a time sufficient for the molten thermoplastic material to cool below its glass transition temperature to form the optical disk; and ejecting the optical disk from the mold apparatus.

Abstract: A molding tool and a method of fabrication thereof which can reduce the fabrication period remarkably, are disclosed. In particular, a molding tool and a method of fabrication thereof which are most suitable for producing a small lot of plastic molded objects used for preparing prototype parts or the like are proposed. Thin die surface layers (20, 30) each having a predetermined die surface shape (C1, C2) are formed by a stereolithography method using a stereolithography material or a powder sinter molding method using a powder molding material. Reinforcing rib portions (25, 35) are formed integrally with the thin die surface layers by the stereolithography method or the powder sinter molding method on the back surface of the thin die surface layers, respectively. Back reinforcement resin layers (26, 36) are filled integrally in the space of the reinforcing rib portions on the back surface of the thin die surface layers.

Abstract: A system to fabricate precise, high aspect ratio polymeric molds by photolithograpic process is described. The molds for producing micro-scale parts from engineering materials by the LIGA process. The invention is a developer system for developing a PMMA photoresist having exposed patterns comprising features having both very small sizes, and very high aspect ratios between part minimum feature size and part overall dimension. The developer system of the present invention comprises a developer tank, an intermediate rinse tank and a final rinse tank, each tank having a source of high frequency sonic agitation, temperature control, and continuous filtration.

Abstract: A film is provided on a mold used during semiconductor device fabrication through surface modifications to the mold to provide non-stick characteristics and a mold surface that is resistant to abrasion or wear. Such surface modifications are particularly useful in a mold having a quartz planar surface adapted to contact a photocurable polymer material applied to a semiconductor wafer surface during a fabrication process. The planar surface of the mold is capable of allowing transmission of ultraviolet light therethrough to cure the polymer material. A non-stick film is formed on the planar surface of the mold by a coating or deposition process in order to modify the mold surface. The non-stick film can be formed of a fluoroalkylsilane compound, or a hard material such as diamond or diamond-like carbon. The non-stick film of diamond or diamond-like carbon provides protection against abrasion or wear on the planar surface of the mold.

Abstract: A mold assembly for forming an ophthalmic lens article includes a first mold and a second mold. The first and second molds are assembled together to define a mold cavity therebetween having a profile corresponding to that of the ophthalmic lens article to be formed. The mold cavity is filled with a polymeric material which is polymerized to form the ophthalmic lens article. At least one of the first and second molds is a resin mold which is formed from a resin material, and a portion of at least a molding surface of the resin mold is directly irradiated with UV radiation so as to provide a UV-treated surface. The ophthalmic lens article formed in the mold cavity is held on the resin mold such that the ophthalmic lens article adheres to the UV-treated surface upon separating the first and second molds away from one another.

Abstract: A light guide plate which is made of a transparent resin and has a first main surface and a second main surface opposite to said first main surface, said first main surface having a surface portion provided with convex portions having a height of 5×10−7 m to 6×10−5 m each and a pitch of 5×10−7 m to 4×10−4 m, each convex portion having a tip portion, and the convex portions of at least 80% of the total convex portions having the tip portions having a radius of curvature of 2×10−6 m or less.

Abstract: In a method of manufacturing a mold for forming an information pattern including servo information or address information on a substrate of a recording medium by being pressed onto the heated substrate, carbon is used as a material for the mold. A mask corresponding to the information pattern is formed on the mold made from carbon of the present invention. Said carbon plate is etched in areas having no mask formed thereon, and lastly the mask is removed.

Abstract: An apparatus and method for the production of ophthalmic lenses, and particularly contact lenses, which minimizes damage of the lens in removal from the mold. The ophthalmic lens is produced in a mold having a male part and a female part that are placed in proximate relation to each other to create a lens-forming cavity. At least the female surface of the female part mold is preferably coated with plasma and is irradiated for a predetermined time such that the female surface and/or surface coating is at least partially cured. Once the female surface, and alternately the male surface and other surfaces of the mold, is at least partially cured, a curable lens-forming material is placed into the lens-forming cavity and cured to form an ophthalmic lens.

Abstract: This invention offers the new molds assembly structure for a plastic art, which enables the both of the complicated design molding process and low material cost of the mold for mass-production by applying the inner silicone rubber portion and the outer plaster portion.

Abstract: Sputtering method and apparatus for depositing a coating onto substrate employs variable magnetic field arranged in vicinity of a cathode within a working chamber, filled with ionizable fluid. By controlling a magnetic field topology, i.e. orientation and value of magnetic strength with respect to cathode there is enabled localization and shifting of plasma away from substrate and by thus improvement of adhesion and properties of deposited coatings.

Abstract: A female mold for plastic sanitaryware manufacture has an open top to promote improved air escape from the mold as resinous backing resin fills the mold in order to reduce the number of gas inclusions within the backing material after it is cured. The female mold also provides thermal insulation for the curing backing material to permit better curing and to reduce the potential for delamination in the finished product. A production fixture is equipped with a gas impermeable lid for selective contact with the female mold, after the air has been expelled from the mold, in order to control undesirable styrene emissions.

Abstract: The invention relates to a method of producing a matrix suitable for use in a plastic element-producing machine, a matrix produced in accordance with the method and use of such a matrix to form a plastic element. One side of the matrix is provided with a negative microstructure which is replicated in plastic material to form a positive microstructure on a plastic element, wherewith the matrix can be produced by applying a layer of material to the positive microstructure side of a master. The positive microstructure side of the master has a thin wear-resistant layer which serves as a first wear surface, wherewith said layer will present irregularities which correspond essentially to the microstructure, and wherein at least said irregularities are filled-in with a plastic composite so as to form a carrier element for supporting the first wear layer. The layer can further be provided with means for supplying heat energy to said matrix.

Abstract: A film is provided on a mold used during semiconductor device fabrication through surface modifications to the mold to provide non-stick characteristics and a mold surface that is resistant to abrasion or wear. Such surface modifications are particularly useful in a mold having a quartz planar surface adapted to contact a photocurable polymer material applied to a semiconductor wafer surface during a fabrication process. The planar surface of the mold is capable of allowing transmission of ultraviolet light therethrough to cure the polymer material. A non-stick film is formed on the planar surface of the mold by a coating or deposition process in order to modify the mold surface. The non-stick film can be formed of a fluoroalkylsilane compound, or a hard material such as diamond or diamond-like carbon. The non-stick film of diamond or diamond-like carbon provides protection against abrasion or wear on the planar surface of the mold.

Abstract: A mold for a microlens includes a substrate at least a portion of which is electrically conductive, such as an electrically-conductive substrate or a substrate with an electrode layer, an insulating mask layer formed on the substrate and including an opening or plural openings, and a plated layer electroplated in the opening and on the mask layer. A first condition that a diameter or width (&phgr;) of the opening has a relation of &phgr;≦0.35R, wherein (R) is a radius of curvature of the plated layer right above the opening, or a second condition that the diameter or width (&phgr;) of the opening is &phgr;≦10 &mgr;m, is met.

Abstract: Lay-up mold comprising a contoured metal frame having an overlying conformal coating of polyurethane.

Abstract: The present invention broadly relates to the mechanical locking and constrainment of an active layer on a given solid surface, wherein the active layer is formed. In addition, disclosed herein is a macrostructured mold with improved heat-absorbing ability comprising a solid base and an active layer disposed on the solid base, wherein the active layer comprises a metal matrix composite formed by the process of infiltrating a powdered preform with a molten infiltrating alloy at an infiltrating temperature, wherein the solid base is formed from material with a melt temperature higher then said infiltration temperature. The solid base further contains one or a plurality of preformed grooves for circulation of cooling fluid, wherein the active layer seals the grooves in the solid base wherein the sealed grooves are designed to contain the cooling fluid thereby providing a mold with improved heat-absorbing ability.

Abstract: Methods are disclosed for rapidly molding chocolate products.

Abstract: The present invention broadly relates to the mechanical locking and constrainment of an active layer on a given solid surface, wherein the active layer is formed. In addition, disclosed herein is a macrostructured mold with improved heat-absorbing ability comprising a solid base and an active layer disposed on the solid base, wherein the active layer comprises a metal matrix composite formed by the process of infiltrating a powdered preform with a molten infiltrating alloy at an infiltrating temperature, wherein the solid base is formed from material with a melt temperature higher than the infiltration temperature. The solid base further contains one or a plurality of preformed grooves for circulation of cooling fluid, wherein the active layer seals the grooves in the solid base wherein the sealed grooves are designed to contain the cooling fluid thereby providing a mold with improved heat-absorbing ability.

Abstract: A device, preferably a micro-device, is molded from a plastic material by injection molding, compression molding or embossing. A microabrader can be molded having microneedles for abrading the stratum corneum of the skin to form an abraded site in the tissue for enhancing drug delivery. The micro-device is molded using a mold assembly having a silicon molding surface. The silicon molding surface can include a recess corresponding to the desired shape and length of the microneedles. The silicon molding surface enables micron and submicron size features to be molded from polymeric materials without the polymeric material adhering to the mold surface. Micro-devices having molded features having micron and submicron dimensions can be rapidly produced without the use of a release agent.

Abstract: A lay-up mold is disclosed. The mold comprises a multi-sided vertically extending frame formed of sheet steel. A plurality of spaced apart vertically extending ribs also formed of sheet steel are positioned within the frame and rigidly affixed thereto, the ribs having upper edges which conform to the shape of the mold surface. The mold also comprises a plurality of spaced apart vertically extending partition elements formed of sheet steel positioned within the frame which transverse the ribs and rigidly and are affixed to the frame, with the partition elements having upper edges which conform to the shape of the mold surface. A layer of perforated sheet steel is rigidly affixed to the frame and the upper edges of the ribs and partition elements, with a coating of polyurethane overlying and bonded to and interlocked with the perforated sheet steel, the coating forming the mold surface.

Abstract: A mold for producing a silicon ingot having a layered structure comprising an inner silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a fine fused silica sand with a particle size of 100-300 &mgr;m is bonded with a silica binder, and an outer silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a coarse fused silica sand with a particle size of 500-1500 &mgr;m is bonded with a silica binder.

Abstract: A plate shaped compression mold, a process for producing the same and a process for making laminate therewith. The plate-shaped compression mold for producing sheet laminate including synthetic resin with a metal coating on at least one surface thereof has a surface for contacting the metal coating of the sheet laminate, which surface has a Rockwell C hardness of higher than about 44 and a thermal coefficient of linear expansion which differs from that of the metal coating by not more than about 2.5×10−6/K, thereby substantially preventing warping or wrinkling of the metal coating during the compression molding process.

Abstract: A mold assembly for forming an ophthalmic lens, the mold assembly comprising a first mold and a second mold which cooperate with each other to define therebetween a mold cavity having a profile following that of the ophthalmic lens, wherein the improvement comprises: at least one of the first and second molds being a coated mold consisting of a body portion including a backing surface having rigidity and mechanical strength enough to withstand a molding operation for forming the ophthalmic lens in the mold cavity, and a thermoplastic film retained on the body portion such that the thermoplastic film covers the backing surface of the body portion, the thermoplastic film having a molding surface which partially defines the mold cavity and which gives a corresponding one of opposite surfaces of the ophthalmic lens.

Abstract: The present invention provides a composite molding tool including a surface coat that comprises metal powders and mineral fillers, and a composition comprising a resin mixture and metallic fillers. The composition includes at least about 45% metallic fillers, based on the weight percent of the total composition.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: Coatings of doped chromium nitride protect forming members such as dies from the corrosive effects of molten aluminum and other reactive metals.

Abstract: An object of the invention is to eliminate a marking process and shorten the time and decrease the cost required for changing contents of marking. An uneven mask is mounted, using a mask set jig, on a mark surface die of the molding die for forming a resin mold package of a semiconductor device. The mark surface die is formed with jig-fixing grooves for mounting the mask set jig. The uneven mask is formed with protrusions and recesses corresponding to the contents of marking to be attached to the surface of the resin mold package. The contents of marking can thus be attached simultaneously with the molding process, and therefore the marking process after molding can be omitted. In accordance with the contents of marking, the uneven mask can be replaced. The time and cost required for changing the contents of marking can thus be reduced.

Abstract: This invention relates to a method for producing cellular molded article in mold pattern of synthetic resin having surface skin which is used, for example, as an automobile interior trim material or the like and a mold pattern for producing thereof. This invention aims to provide a method for producing cellular molded article of synthetic resin having surface skin which has good production efficiency and which comprises that cellular molded article of synthetic resin obtained by cellular molding of expanded beads in which poor melt bonding does not occur and thermoplastic resin skin material united with this cellular molded article of synthetic resin which has excellent appearance without residing beads pattern on its surface, and a mold used for producing thereof.

Abstract: A female mold substrate used for the production of a microprobe tip or probe detecting a tunneling current or weak force includes a substrate provided with a recess section and a heat-flowable layer having flowability by heat treatment formed on the substrate and covering the recess. The female mold substrate is made by forming a recess section on the top surface of a substrate and forming a heat-flowable layer on the top surface of the substrate including the recess section. A microprobe tip detecting a tunneling current or weak force is made by forming a tip material layer on the female mold substrate and transferring the tip of material layer onto another substrate.

Abstract: A mold used for manufacturing an inorganic board and a method of manufacturing an inorganic board by employing said mold are provided in the present invention. Said mold consists of a mold part made of a fiber reinforced plastic and a metal part attached to the back of said mold part, and because of said metal part, the difference in the coefficient of thermal expansion between said mold and an inorganic board manufactured on said mold is small.

Abstract: The present invention broadly relates to the mechanical locking and constrainment of an active layer on a given solid surface, wherein the active layer is formed. In addition, disclosed herein is a macrostructured mold with improved heat-absorbing ability comprising a solid base and an active layer disposed on the solid base, wherein the active layer comprises a metal matrix composite formed by the process of infiltrating a powdered preform with a molten infiltrating alloy at an infiltrating temperature, wherein the solid base is formed from material with a melt temperature higher than the infiltration temperature. The solid base further contains one or a plurality of preformed grooves for circulation of cooling fluid, wherein the active layer seals the grooves in the solid base wherein the sealed grooves are designed to contain the cooling fluid thereby providing a mold with improved heat-absorbing ability.