Super-imposed Metal Layers Patents (Class 249/116)
  • Patent number: 10399253
    Abstract: A multi-layered composite mold structure (10) is provided. The multi-layered composite mold structure (10) comprises a multi-layered member including (a) at least one metal heating layer (11); (b) at least one metal heat distribution layer (13); (c) at least one laminate composite layer (12); and (d) a surface layer (14). A process for preparing the multi-layered composite mold structure is also provided.
    Type: Grant
    Filed: August 29, 2013
    Date of Patent: September 3, 2019
    Assignee: Dow Global Technologies LLC
    Inventors: Demei Xie, Liangkai Ma
  • Publication number: 20150115129
    Abstract: A coated diamond-turned replication master for manufacturing wafer level lens arrays includes a low-hardness diamond-turnable sheet, a mold surface formed in the low-hardness diamond-turnable sheet, and an oxidation-resistant coating formed on the mold surface for protecting same. The mold surface includes a plurality of optical forms, all of which cut therein by a single diamond cutting tool. A process for forming a coated diamond-turned replication master includes a step of forming a mold surface in a low-hardness diamond-turnable sheet using a single diamond cutting tool. The mold surface includes a plurality of optical forms, all of which are formed by the single diamond cutting tool. The process also includes, after the step of forming a plurality of optical forms, coating the mold surface with an oxidation-resistant coating.
    Type: Application
    Filed: October 14, 2014
    Publication date: April 30, 2015
    Inventors: George Barnes, Donald Combs, Michael Rickers, Elizabeth Zachary
  • Publication number: 20150102202
    Abstract: The present invention provides a heat insulated mold having a zirconia insulated layer, the deterioration of which is effectively limited or prevented. The present invention relates to a heat insulated mold having a heat insulating layer between a metal mold base material and a metal film forming a molding surface, wherein: (1) the insulating layer contains zirconia; and (2) a water-blocking layer for blocking entrance of water from the metal film to the heat insulating layer is provided between the heat insulating layer and the metal film.
    Type: Application
    Filed: May 19, 2014
    Publication date: April 16, 2015
    Applicant: KOBE CERAMICS CORPORATION
    Inventors: Hideo Torii, Takayoshi Suzuki
  • Patent number: 8948562
    Abstract: The present invention provides templating methods for replicating patterned metal films from a template substrate such as for use in plasmonic devices and metamaterials. Advantageously, the template substrate is reusable and can provide plural copies of the structure of the template substrate. Because high-quality substrates that are inherently smooth and flat are available, patterned metal films in accordance with the present invention can advantageously provide surfaces that replicate the surface characteristics of the template substrate both in the patterned regions and in the unpatterned regions.
    Type: Grant
    Filed: November 24, 2009
    Date of Patent: February 3, 2015
    Assignee: Regents of the University of Minnesota
    Inventors: David J. Norris, Sang Eon Han, Aditya Bhan, Prashant Nagpal, Nathan Charles Lindquist, Sang-Hyun Oh
  • Patent number: 8899546
    Abstract: A mold for molding a wind turbine blade, the mold comprising a mold body having a front molding surface and a rear face, the mold body having at least one tube therein for conveying a heating liquid therethrough, the at least one tube defining a plurality of laterally spaced heating elements, and a continuous layer of heat conductive material located in the thickness direction of the mold body between the plurality of laterally spaced heating elements and the front molding surface and extending laterally across the space between adjacent heating elements.
    Type: Grant
    Filed: September 9, 2010
    Date of Patent: December 2, 2014
    Assignee: Suzhou Red Maple Wind Blade Mould Co., Ltd.
    Inventor: Gabriel Mironov
  • Patent number: 8851442
    Abstract: The invention is directed to a patterned aerogel-based layer that serves as a mold for at least part of a microelectromechanical feature. The density of an aerogel is less than that of typical materials used in MEMS fabrication, such as poly-silicon, silicon oxide, single-crystal silicon, metals, metal alloys, and the like. Therefore, one may form structural features in an aerogel-based layer at rates significantly higher than the rates at which structural features can be formed in denser materials. The invention further includes a method of patterning an aerogel-based layer to produce such an aerogel-based mold. The invention further includes a method of fabricating a microelectromechanical feature using an aerogel-based mold. This method includes depositing a dense material layer directly onto the outline of at least part of a microelectromechanical feature that has been formed in the aerogel-based layer.
    Type: Grant
    Filed: January 22, 2008
    Date of Patent: October 7, 2014
    Assignee: Honeywell International Inc.
    Inventor: Robert J. Carlson
  • Patent number: 8844897
    Abstract: Devices may be in contact with molten metals such as copper, for example. The devices may include, but are not limited to, a die used for producing articles made from the molten metal, a sensor for determining an amount of a dissolved gas in the molten metal, or an ultrasonic device for reducing gas content (e.g., hydrogen) in the molten metal. Niobium may be used as a protective barrier for the devices when they are exposed to the molten metals.
    Type: Grant
    Filed: March 4, 2009
    Date of Patent: September 30, 2014
    Assignee: Southwire Company, LLC
    Inventors: Victor F. Rundquist, Kevin S. Gill
  • Patent number: 8708691
    Abstract: A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a temperature control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A resin transfer system delivers resin from a resin source to the tooling dies to allow resin transfer molding. A composite fabrication method is also disclosed.
    Type: Grant
    Filed: December 20, 2012
    Date of Patent: April 29, 2014
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Kim E. Peterson, William Dykstra
  • Patent number: 8679221
    Abstract: A method for producing an alumina template of nanorods, the alumina template, and the nanorods are provided for overcoming the problems of the conventional alumina template having anodic aluminum oxide that may be peeled off from a substrate or forming a non-conductive oxide easily, and the alumina template includes a conductive substrate composed of an active metal and an inert metal, so that the alumina template can be attached onto the active metal and inert metal at the same time, and the active metal can be used for securing the alumina template and supporting the alumina template on the inert metal, and the anodic aluminum oxide attached onto the inert metal can be used for providing a better conductivity, such that a stable and highly conductive alumina template can be produced.
    Type: Grant
    Filed: December 13, 2011
    Date of Patent: March 25, 2014
    Assignee: Southern Taiwan University
    Inventors: Hsyi-en Cheng, Bo-jiun Yeh
  • Patent number: 8556619
    Abstract: A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a thermal control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A composite fabrication method is also disclosed.
    Type: Grant
    Filed: July 6, 2011
    Date of Patent: October 15, 2013
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Kim E. Peterson, William Dykstra
  • Publication number: 20130145900
    Abstract: A method for producing an alumina template of nanorods, the alumina template, and the nanorods are provided for overcoming the problems of the conventional alumina template having anodic aluminum oxide that may be peeled off from a substrate or forming a non-conductive oxide easily, and the alumina template includes a conductive substrate composed of an active metal and an inert metal, so that the alumina template can be attached onto the active metal and inert metal at the same time, and the active metal can be used for securing the alumina template and supporting the alumina template on the inert metal, and the anodic aluminum oxide attached onto the inert metal can be used for providing a better conductivity, such that a stable and highly conductive alumina template can be produced.
    Type: Application
    Filed: December 13, 2011
    Publication date: June 13, 2013
    Inventors: Hsyi-en CHENG, Bo-jiun YEH
  • Patent number: 8449284
    Abstract: An optical element molding die is designed for molding an optical element having a concave-convex structure. The optical element can be manufactured by a wet system that enables element formation over a large area and a curved surface, without using a lithographic process, and is advantageous in terms of mass production and equipment cost. The optical element molding die includes a substrate having a surface with a negative standard electrode potential in the oxidation reaction and an anodic oxidation layer provided on the substrate. A protective layer with the positive standard electrode potential is provided between the substrate and the anodic oxidation layer.
    Type: Grant
    Filed: November 6, 2009
    Date of Patent: May 28, 2013
    Assignee: Canon Kabushiki Kaisha
    Inventor: Masanobu Ohgane
  • Patent number: 8262382
    Abstract: A stamper, used for fabricating an antireflective member, has an uneven surface pattern, which includes a plurality of very small recessed portions, each having a stepped side surface.
    Type: Grant
    Filed: March 26, 2009
    Date of Patent: September 11, 2012
    Assignee: Sharp Kabushiki Kaisha
    Inventors: Tokio Taguchi, Shun Ueki, Kozo Nakamura, Kazuhiko Tsuda
  • Publication number: 20120218639
    Abstract: A moth-eye mold fabrication method includes: (a) providing an aluminum film deposited on a base, the aluminum film having a thickness of not less than 0.5 ?m and not more than 5 ?m, a surface of the aluminum film having a plurality of crystal grains whose average crystal grain diameter is not less than 200 nm and not more than 5 ?m; (b) after step (a), anodizing the surface of the aluminum film to form a porous alumina layer which has a plurality of minute recessed portions; and (c) after step (b), bringing the porous alumina layer into contact with an etching solution, thereby enlarging the plurality of minute recessed portions of the porous alumina layer. A method of readily fabricating a mold is produced that is for manufacture of an antireflection film in which a moth-eye structure is superposed over an antiglare structure.
    Type: Application
    Filed: October 27, 2010
    Publication date: August 30, 2012
    Applicant: SHARP KABUSHIKI KAISHA
    Inventors: Kiyoshi Minoura, Akinobu Isurugi
  • Publication number: 20120200932
    Abstract: A mold includes an anodized porous alumina layer over its surface. The anodized porous alumina layer has a plurality of first and second recessed portions. The plurality of second recessed portions have a two-dimensional size of not less than 190 nm and not more than 50 ?m when viewed in a direction normal to the mold surface and have a plurality of minute recessed portions over its inner surface. The plurality of minute recessed portions have a two-dimensional size of not less than 10 nm and not more than 200 nm; and have a two-dimensional size of not less than 10 nm and not more than 200 nm. The plurality of first recessed portions are provided between the plurality of second recessed portions. The average value of the two-dimensional size of the plurality of second recessed portions is greater than that of the plurality of first recessed portions.
    Type: Application
    Filed: October 12, 2010
    Publication date: August 9, 2012
    Applicant: SHARP KABUSHIKI KAISHA
    Inventors: Chiaki Minari, Tokio Taguchi
  • Patent number: 8070476
    Abstract: A thermal insulation stamper includes a first metal layer, a heat insulating layer, an intermediate layer, a conductive coating, and a second metal layer. The first metal layer has a fine pattern on an exposed surface. The heat insulating layer is formed of a heat-resistant resin and overlies the first metal layer. The heat-resistant resin contains oxygen. The intermediate layer overlies the heat insulating layer. The conductive coating overlies the intermediate metal layer. The second metal layer overlies the conductive coating. A region with a high concentration of oxygen is formed in the vicinity of an interface between the heat insulating layer and the intermediate layer. A method for producing such a thermal insulation stamper is also disclosed.
    Type: Grant
    Filed: September 12, 2008
    Date of Patent: December 6, 2011
    Assignee: Ricoh Company, Ltd.
    Inventors: Kazuhiro Kotaka, Yuzuru Kudoh
  • Patent number: 7922146
    Abstract: A method of forming an optical element forming metal mold to form an optical element, having steps of: laminating a heat insulation layer 13 on a surface of the base member 11 where the optical element is formed; laminating an intermediate metal layer 14 on a surface of the heat insulation layer 13 by thermal spraying; laminating a surface forming layer 15, on which a surface shape to be transferred to the optical element is formed, on the intermediate metal layer 14; wherein the intermediate metal layer 14 is laminated in a way that parts of the heat insulation layer 13 are exposed substantially evenly from the intermediate layer 14.
    Type: Grant
    Filed: March 26, 2008
    Date of Patent: April 12, 2011
    Assignee: Konica Minolta Opto, Inc.
    Inventors: Masayoshi Uehira, Yuzo Nakatsuka
  • Publication number: 20110046764
    Abstract: A process to manufacture a 3D mold to fabricate a high-throughput and low cost sub-micron 3D structure product is disclosed. The process integrates use of 2-photon laser lithography and 3D write technology to make a 3D mold of each layer of the 3D structure product, and then use nanoimprinting to form a sheet of polymer film of each layer of the 3D structure from the said 3D mold of that layer. Each layer of the sheet of polymer film is then fabricated into the sub-micron 3D structure product. The 3D mold of each layer of a high-throughput and low cost sub-micron 3D structure product, is further used to make master molds which is then used to form a sheet of polymer film of each layer of the 3D structure to fabricate the sub-micron 3D structure product. Applications using this process are also disclosed.
    Type: Application
    Filed: November 23, 2009
    Publication date: February 24, 2011
    Applicant: HELIOS APPLIED SYSTEMS PTE LTD
    Inventor: Shyi-Herng Kan
  • Patent number: 7784765
    Abstract: There is provided a mold which contains at least two electroforming layers, wherein the mold has a concavo-convex pattern on a surface thereof, and the electroforming layers include at least two adjacent layers having the same crystal orientation.
    Type: Grant
    Filed: November 28, 2007
    Date of Patent: August 31, 2010
    Assignee: FUJIFILM Corporation
    Inventors: Kenji Ichikawa, Seiji Kasahara
  • Publication number: 20100119782
    Abstract: An optical element molding die is designed for molding an optical element having a concave-convex structure. The optical element can be manufactured by a wet system that enables element formation over a large area and a curved surface, without using a lithographic process, and is advantageous in terms of mass production and equipment cost. The optical element molding die includes a substrate having a surface with a negative standard electrode potential in the oxidation reaction and an anodic oxidation layer provided on the substrate. A protective layer with the positive standard electrode potential is provided between the substrate and the anodic oxidation layer.
    Type: Application
    Filed: November 6, 2009
    Publication date: May 13, 2010
    Applicant: CANON KABUSHIKI KAISHA
    Inventor: Masanobu Ohgane
  • Patent number: 7704066
    Abstract: A heat insulating stamper is disclosed. The heat insulating stamper includes an uppermost section made of a metal material, a lowermost section made of the same material as the uppermost section, and a middle section having a heat conductivity lower than the uppermost section. The middle section includes the same metal material as the uppermost section and the lowermost section, and heat insulating portions.
    Type: Grant
    Filed: October 19, 2005
    Date of Patent: April 27, 2010
    Assignee: Ricoh Company, Ltd.
    Inventors: Shigeru Fujita, Kazuhiro Kotaka, Nobuhiro Tanaka
  • Patent number: 7687007
    Abstract: Method for manufacturing a mold tool (1), devised for forming a structured nanoscale pattern on an object (24) and having a layer (16) which is anti-adhesive with regard to the object (24). A stamp blank (2) is provided with a structured pattern (4) on a surface (8). The patterned surface (8) is coated with a layer (6) of a metal, which has a stable oxidation number and can form a mechanically stable oxide film. The metal layer (6) is oxidized for forming of an oxide film (10). The oxide film (10) is exposed to a reagent comprising molecule chains (18), each of which has a linkage group (20) which bonds to the oxide film (10) by chemical bonding, wherein the molecule chains (18) either at the outset comprise at least a group (22) comprising fluorine, or in a subsequent step is provided with at least one such group (22).
    Type: Grant
    Filed: June 16, 2003
    Date of Patent: March 30, 2010
    Assignee: Obducat AB
    Inventors: Torbjörn Ling, Lars Montelius, Matthias Keil, Marc Beck
  • Patent number: 7648117
    Abstract: A cavity is formed between stationary and movable mold members, and a runner is connected to a gate to the mold cavity to supply a molten resin material thereto. The stationary and movable mold members have bodies of an aluminum alloy of high heat conductivity and light weight. Iron base plating is applied at least to transfer wall surfaces of the cavity, leaving and exposing other wall surfaces in a non-plated state.
    Type: Grant
    Filed: December 12, 2007
    Date of Patent: January 19, 2010
    Assignee: Nippon Platec Co., Ltd.
    Inventors: Wataru Oikawa, Tsuyoshi Namioka
  • Patent number: 7641169
    Abstract: A preparing method for a substrate for a stamper where the entirety of the metal rolled plate can be used as the material for the substrate so that a high yield in the preparation can be maintained is provided. A metal is rolled so as to generate a metal rolled plate, the metal rolled plate that is generated is cut to a predetermined size, and metal plating is operated on the front surface or the rear surface, or both the front and rear surfaces, of the metal rolled plate that has been cut to a predetermined size, and then, a polishing process is operated. A target plate thickness that is set when the metal rolled plate is rolled is smaller than the plate thickness that is required at the time of completion of the polishing process.
    Type: Grant
    Filed: November 29, 2005
    Date of Patent: January 5, 2010
    Assignee: Sumitomo Metal Industries, Ltd.
    Inventors: Futoshi Katsuki, Kunihiro Fukui, Atsuhiko Kuroda
  • Publication number: 20090289029
    Abstract: A mold is for obtaining, on a substrate, an array of carbon nanotubes with a high control of their positioning. The mold includes a first layer of a first preset material having a surface having in relief at least one first plurality of projections having a free end portion with a substantially pointed profile.
    Type: Application
    Filed: March 30, 2009
    Publication date: November 26, 2009
    Applicant: STMicroelectronics S.r.l.
    Inventors: Raffaele VECCHIONE, Luigi OCCHIPINTI
  • Publication number: 20090122310
    Abstract: Provided is a method of making microarrays that includes providing a substrate with discrete first microfeatures that have a first profile, and depositing vapor-coated materials onto the first microfeatures to form second microfeatures having a second profile that is substantially different from the first profile. Also provided is a method of adding a replication material to the vapor-coated microfeatures to form a mold. Microarrays made by this method can be used as substrates for surface-enhanced Raman spectroscopy (SERS).
    Type: Application
    Filed: October 7, 2008
    Publication date: May 14, 2009
    Inventors: Jun-Ying ZHANG, Terry L. Smith, Haiyan Zhang, Jerome C. Porque, Ding Wang, John C. Hulteen, Lisa A. Dick
  • Publication number: 20090001619
    Abstract: The invention provides: a mold for molding optical glass, the mold comprising: a mold base; and a protective film comprising one or two or more layers formed on the mold base, the outermost layer of the protective film containing one or more elements selected from the group consisting of Al, Ga, In, Tl, Ge, Sn, Pb, As, Sb, Bi, S, Se, and Te; a process for producing the mold; and a process for press-molding with the mold.
    Type: Application
    Filed: August 28, 2008
    Publication date: January 1, 2009
    Applicant: ASAHI GLASS COMPANY, LIMITED
    Inventor: Sunao MIYAZAKI
  • Publication number: 20080143020
    Abstract: There is provided a mold which contains at least two electroforming layers, wherein the mold has a concavo-convex pattern on a surface thereof, and the electroforming layers include at least two adjacent layers having the same crystal orientation.
    Type: Application
    Filed: November 28, 2007
    Publication date: June 19, 2008
    Applicant: FUJIFILM Corporation
    Inventors: Kenji ICHIKAWA, Seiji KASAHARA
  • Patent number: 7377477
    Abstract: Product forming molds have surfaces conformally coated with a coating composite comprising superabrasive particles. In one embodiment, the mold surface is plated (electrolessly or electrolytically) or coated with a metal having superabrasive particles dispersed therein. In another embodiment, the composite is a SiC composite having superabrasive particles dispersed therein.
    Type: Grant
    Filed: February 11, 2005
    Date of Patent: May 27, 2008
    Assignee: Diamond Innovations, Inc.
    Inventors: John William Lucek, Marc Gary Davidson, Timothy F. Dumm
  • Publication number: 20070216045
    Abstract: Compositions and methods for improving demolding polar resin molds used in the production of silicone hydrogel materials are described. The present compositions and methods include the use of one or more reactive demolding agents. The reactive demolding agents react with components of a polymerization mixture to produce a polymerized silicone hydrogel device containing a reactant product of the demolding agent and the other components of the polymerization mixture. Polar resin molds used during the polymerization of the polymerization mixture are more easily separated than substantially identical molds used in the polymerization of a substantially identical material without a reactive demolding agent. The present compositions and methods may be used in the manufacture of silicone hydrogel lenses, such as contact lenses. The demolding aids may also be useful as delensing aids.
    Type: Application
    Filed: March 15, 2007
    Publication date: September 20, 2007
    Inventor: Charles A. Francis
  • Publication number: 20070193304
    Abstract: To provide a glass molding die which is more excellent in durability than the conventional ones. A glass molding die 10 includes a base body 12, an Au layer 14 which is laminated on a surface of the base body 12, and an Rh layer 16 which is laminated on a surface of the Au layer 14. On a surface of the Rh layer 16, an Ir-containing layer may be further laminated. The Au layer 14 functions as a bonding layer, the Rh layer 16 functions as an anti diffusion layer, and the Ir-containing layer functions as a mold releasing layer. The Au layer 14, the Rh layer 16, and the Ir-containing layer are preferably formed by plating.
    Type: Application
    Filed: February 7, 2007
    Publication date: August 23, 2007
    Applicant: TOKAI RUBBER INDUSTRIES, LTD.
    Inventors: Hiroki Itakura, Ryo Minoshima
  • Patent number: 7220116
    Abstract: Injection moulding mould part consisting of a mirror and a venting ring that can be moved with respect thereto. A wear-resistant coating has been applied to the mirror and/or the interface between the two parts that can be moved with respect to one another. This coating consists of hard metal based on tungsten with a minimum thickness of 0.01 mm and more particularly with a thickness of at least 0.1 mm. This coating is applied with an HP-HVOF process (High Velocity Oxygen Fuel).
    Type: Grant
    Filed: September 12, 2005
    Date of Patent: May 22, 2007
    Assignee: Axxicon Moulds Eindhoven B.V.
    Inventors: Herm Adrianus Tijl, Marcelis Johannes Van Rijt, Henricus Johanna Wijnanda Van De Mortel
  • Patent number: 7178780
    Abstract: A mold used to form a magnetic member includes a mold body having a mold opening, a mold support that supports the mold cavity, and a mold insert. The mold insert is disposed in the mold opening of the mold body to form a mold cavity. The mold insert is coated with a coating to protect the mold body from chemical attack and abrasive wear of the mold material. The coating comprises an electroless nickel layer formed on or over the mold insert, and a chromium nitride layer formed on or over the electroless nickel layer. The mold insert can be formed of beryllium-copper (Be—Cu).
    Type: Grant
    Filed: March 31, 2004
    Date of Patent: February 20, 2007
    Assignee: Xerox Corporation
    Inventors: Paul F. Mastro, Christopher D. Blair, Jennifer R. Wagner, Jay Schneider
  • Patent number: 7124994
    Abstract: The present invention describes a method for rapidly fabricating a robust 3-dimensional silicon-mold for use in preparing complex metal micro-components. The process begins by depositing a conductive metal layer onto one surface of a silicon wafer. A thin photoresist and a standard lithographic mask are then used to transfer a trace image pattern onto the opposite surface of the wafer by exposing and developing the resist. The exposed portion of the silicon substrate is anisotropically etched through the wafer thickness down to conductive metal layer to provide an etched pattern consisting of a series of rectilinear channels and recesses in the silicon which serve as the silicon micro-mold. Microcomponents are prepared with this mold by first filling the mold channels and recesses with a metal deposit, typically by electroplating, and then removing the silicon micro-mold by chemical etching.
    Type: Grant
    Filed: December 15, 2004
    Date of Patent: October 24, 2006
    Assignee: Sandia National Laboratories
    Inventor: Alfredo M. Morales
  • Patent number: 6861021
    Abstract: An molding apparatus useful for molding polymer compositions includes a substrate; a first insulating layer having an electrical resistivity of at least about 1010 ohm-centimeters and thermal conductivity of about 0.2 to about 5 watts/(meter-kelvin); a heating element; a second insulating layer having an electrical resistivity of at least about 1010 ohm-centimeters and a thermal conductivity of at least about 5 watts/(meter-kelvin); and a first molding layer having a specific heat capacity of about 100 to about 2,500 joules/(kilogram-kelvin), and optionally, a second molding layer. The apparatus provides rapid heating and cooling of the mold surface. The apparatus may be employed for rapidly molding articles having desirable surface characteristics.
    Type: Grant
    Filed: February 13, 2003
    Date of Patent: March 1, 2005
    Assignee: General Electric Company
    Inventors: Iain Montgomery, Peter James Zuber
  • Publication number: 20040051026
    Abstract: A mold construction is provided having a layered configuration including a substrate or mold core preferably of ampcoloy, an intermediate or primer coat preferably of electroless nickel, and an outer mold surface layer made of a high strength metal preferably of titanium. The mold construction is particularly advantageous for use in molding glass objects. The electroless nickel undercoat or primer coat serve to adhere the softer ampcoloy substrate to the high strength outer layer of titanium alloy. The electroless nickel also provides some elasticity for the outer layer of titanium alloy layer to reduce cracking and flaking of the titanium alloy. The layer of titanium alloy provides good strength and durability to withstand abrasive contact with the molten glass, while the ampcoloy still facilitates high thermal conductivity for reducing mold cycle times.
    Type: Application
    Filed: September 18, 2002
    Publication date: March 18, 2004
    Inventor: Robert William Flynn
  • Publication number: 20030215664
    Abstract: The present invention describes a method for fabricating an embossing tool or an x-ray mask tool, providing microstructures that smoothly vary in height from point-to-point in etched substrates, i.e., structure which can vary in all three dimensions. The process uses a lithographic technique to transfer an image pattern in the surface of a silicon wafer by exposing and developing the resist and then etching the silicon substrate. Importantly, the photoresist is variably exposed so that when developed some of the resist layer remains. The remaining undeveloped resist acts as an etchant barrier to the reactive plasma used to etch the silicon substrate and therefore provides the ability etch structures of variable depths.
    Type: Application
    Filed: May 14, 2002
    Publication date: November 20, 2003
    Inventors: Alfredo M. Morales, Marcela Gonzales
  • Patent number: 6613266
    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.
    Type: Grant
    Filed: July 2, 1998
    Date of Patent: September 2, 2003
    Assignee: Metallamics
    Inventor: Robert R. McDonald
  • Publication number: 20030132363
    Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.
    Type: Application
    Filed: January 21, 2003
    Publication date: July 17, 2003
    Inventors: Phillip E. Kenney, Jeffrey D. Fletcher, Dennis R. Malone, Lawrence B. Wilson
  • Patent number: 6591636
    Abstract: An oxidation and corrosion resistant coating is applied to glass forming equipment by physical vapor deposition. The coating material is preferably aluminum oxide.
    Type: Grant
    Filed: November 3, 2000
    Date of Patent: July 15, 2003
    Assignee: Corning Incorporated
    Inventors: Dominick J. Forenz, Anca D. Fountain, Sherry J. Gill, Kenneth R. Salisbury, Ahmad Sarhangi, Kim E. Womer
  • Patent number: 6523804
    Abstract: A method of patterning metallic building elements, and also to a metallic building element, where the measuring accuracy achieved can lie in the sub-micrometer range is disclored. Starting from a silicon master or original that can be etched to sub-micrometer precision and then plated with a metal, such as nickel, on the silicon surface, there can be produced a nickel shim where precision and surface fineness can lie in the sub-micrometer range. Subsequent to removal of the silicon master, a photo-sensitive material can be used in liquid form or in film form to create mould cavities that reach down to the nickel shim. These cavities can then be metal-plated to provide a building element of higher precision in three dimensions.
    Type: Grant
    Filed: August 17, 1999
    Date of Patent: February 25, 2003
    Assignee: Telefonaktiebolaget LM Ericsson (publ)
    Inventors: Claes Blom, Christian Vieider, Olov Larsson
  • Publication number: 20030025226
    Abstract: Method comprises:
    Type: Application
    Filed: April 30, 2001
    Publication date: February 6, 2003
    Inventors: Hao Wen Chiu, Hsinjin Edwin Yang
  • Publication number: 20030010469
    Abstract: The invention relates to a device for casting a workpiece, especially a turbine blade with inner cooling, comprising a casting cavity (1) in which casting cores (2) which produce channels (3) that pass through the workpiece are provided. The aim of the invention is to improve a device of this type in such a way that there are no poorly cooled areas present in the workpiece. To this end, the casting cores (2) are placed in the casting cavity (1) in such a way that they rest against each other loosely.
    Type: Application
    Filed: August 23, 2002
    Publication date: January 16, 2003
    Inventor: Peter Tiemann
  • Patent number: 6499715
    Abstract: A resin mold has a surface layer formed on the molding surface of a main body from a thermosetting resin and containing fine particles of silicon carbide. The surface layer can be formed simply by thermosetting the resin without calling for any plating, so that the mold can be made in a short time. The high hardness of silicon carbide gives a high wear resistance to the surface layer. The main body is formed from a thermosetting resin and contains metal particles.
    Type: Grant
    Filed: December 14, 1999
    Date of Patent: December 31, 2002
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Tamio Furuya, Kenichi Chujo, Kazushiro Wakabayashi, Satoru Yamada, Hiroe Hashimoto
  • Publication number: 20020179449
    Abstract: A sacrificial plastic mold having an electroplatable backing is provided as are methods of making such a mold via the infusion of a castable liquid formulation through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale master mold. Upon casting and demolding, the porous metal substrate is embedded within the cast formulation and projects a plastic structure with features determined by the mold tool. The plastic structure provides a sacrificial plastic mold mechanically bonded to the porous metal substrate, which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved, leaving the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.
    Type: Application
    Filed: January 17, 2002
    Publication date: December 5, 2002
    Inventors: Linda A. Domeier, Alfredo M. Morales, Marcela G. Gonzales, Patrick N. Keifer
  • Publication number: 20020100858
    Abstract: A double-shell nickel mold produced by nickel vapor depositoin. A first nickel shell is deposited on a mandrel, heating/cooling lines are attached to the first nickel shell, a thermally-conductive filler is applied to fill all gaps between the heating/cooling lines and the first nickel shell, and a second nickel shell is deposited on the first nickel shell to encapsulate the heating/cooling lines.
    Type: Application
    Filed: January 29, 2001
    Publication date: August 1, 2002
    Inventor: Reinhart Weber
  • Publication number: 20020100859
    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.
    Type: Application
    Filed: July 26, 1999
    Publication date: August 1, 2002
    Inventors: TAKAYUKI YAGI, YASUHIRO SHIMADA, TAKAYUKI TESHIMA, TAKASHI USHIJIMA
  • Patent number: 6406732
    Abstract: Methods are disclosed for rapidly molding chocolate products.
    Type: Grant
    Filed: January 6, 2000
    Date of Patent: June 18, 2002
    Assignee: Mars Incorporated
    Inventors: Ralph D. Lee, Tracy D. B. Ziener, Neil A. Willcocks, William Harding, Frank W. Earis, Thomas M. Collins
  • Publication number: 20010020525
    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.
    Type: Application
    Filed: May 24, 2001
    Publication date: September 13, 2001
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Patent number: 6119485
    Abstract: A press-molding die comprises a base material, an intermediate layer formed on a surface of the base material and a protective layer formed on the intermediate layer. The base material comprises an inorganic oxide. The intermediate layer comprises a material that adheres to both the base material and the protective layer and is heat resistant at high temperatures wherein the die is used. The protective layer comprises at least one metal film selected from the group consisting of tungsten (W), platinum (Pt), palladium (Pd), rhodium (Rh), ruthenium (Ru), iridium (Ir), osmium (Os), rhenium (Re), tantalum (Ta) and alloys thereof.
    Type: Grant
    Filed: February 19, 1998
    Date of Patent: September 19, 2000
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Kunio Hibino, Makoto Umetani, Hidenao Kataoka