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: 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.

Abstract: A method for producing a multiplicity of miniature cavities extending from a mold surface for molding a plastic product having features integrally molded with and extending from a product base, and a mold so produced. The mold cavities are formed by depositing multiple layers of plating material on a workpiece in a predetermined pattern selected to produce a desired mold cavity shape. The mold may be in the form of a roll or belt for continuous processing, or in any form for discrete injection molding. The invention is particularly applicable to the production of touch fastener products, such as those with arrays of miniature hooks.

Abstract: A die for press-molding glass optical elements comprising (a) a base material having heat resistance and sufficient strength to withstand press-molding of optical glass elements; (b) a film on said base material comprising an alloy film containing B and one metal selected from the group consisting of Ni, Co, and Fe, and one metal selected from the group consisting of Si, Ti, Cu, Zr, Nb, Mo, Ru, Rh, Pd, Hf, Ta, W, Re, Os, and Ir, to form a cutting layer; and (c) a surface protective layer on top of said cutting layer made of an alloy film comprising at least one metal selected from the group consisting of Pt, Pd, Ir, Rh, Os, Ru, Re, W, and Ta.

Abstract: A method for producing diffractive optic molding tools with improved durability is accomplished by depositing a layer of chromium carbide on a substrate material. This layer of chromium carbide becomes the receptor for a final machinable coating such as electroless nickel. The pattern for the desired diffractive surface is predetermined and a single-point-diamond turning machine is used to cut the negative of this predetermined pattern into the machinable layer to produce the pattern of concentric zones to the required depths. The pattern is then uniformly etched in the machinable layer down into the intermediate layer of chromium carbide resulting in the complete removal of all of the electroless nickel. In that the etching rates of electroless nickel and chromium carbide differ from one another, it is necessary to dimensionally adjust the negative pattern turned into the electroless nickel surface to allow for the different etch rates.

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 plate for press-moulding dies of refractory bricks and the like, including a bearing metal slab to one face of which a lining of high wear-resistant material, normally hard metal, is applied, which is formed by a number of adjacent tiles arranged in an orderly way along parallel lines. The adjoining sides between adjacent tiles are at least in part curved.

Abstract: There is provided a stamper for producing a recording medium exhibiting excellent durability and capable of stably forming projections and pits and a method of producing the stamper. A stamper for producing a recording medium comprising projections and pits in a predetermined pattern on the surface thereof, wherein a value of tan .theta..sup.-1 obtainable from an enlargement angle .theta. of an output from a cartridge with respect to an enlargement of an output denoting a load measured by a test of scratching the surface having the projections and pits under conditions that a diameter of a stylus is 100 .mu.m and a loading speed of 1 .mu.m/second is 1.3 or more.

Abstract: A method of forming a nickel shell for a mold insert to reproduce an article surface, and a novel nickel shell insert are disclosed. The method comprises securing the article to be reproduced to a base having a perimeter, forming a dam about the perimeter, filling the interior of the dam with a silicone, mounting a register plate over the article within the dam in contact with the silicone, and allowing the silicone to cure whereby the silicone forms a negative master of the article surface, removing the negative master from the article and positioning a steel mandrel over the negative master to define a cavity therebetween, feeding a silicone which is not adherent to the negative master into said cavity to fill the cavity and allowing the silicone to cure whereby the silicone forms a positive master which adheres to the steel mandrel, removing the negative master from the positive master, and depositing a layer of nickel by nickel vapour deposition onto the positive master to form a nickel shell.

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: An apparatus for molding polystyrene mold halves which are used, for subsequent molding of a soft contact lens. The apparatus is designed with superior heat conduction capacity so as to minimize the molding cycle time, while simultaneously producing uniformly precise and accurate optical quality surfaces. Molten polystyrene is provided via a hot runner system to a plurality of mold cavities. In a specific variation, the convex surface provides the optical quality surface to the concave surface of the mold half produced thereby. The structural element which defines the convex surface includes a hollow cylindrical bushing and a removable power insert mounted therein, which may be changed so that the prescription strength of the contact lens to be formed by the mold may be varied. In a first embodiment, the power insert includes only a convex surface at its operational end.

Abstract: A die for press-molding glass optical elements which can press-mold glass optical elements having high melting points and various shapes repeatedly, which includes a base material having high strength on which a cutting layer having heat resistance and free cutting machinability is formed. After cutting the cutting layer into the desired shape with high accuracy, the die is coated with a surface protective film.

Abstract: A lightweight thermally responsive mold for use with a resin transfer molding process is provided. The mold includes first and second support frames including a plurality of upstanding intersecting support ribs. First and second substrates are supported by the first and second support frames, respectively, for carrying heating tubes therein. First and second hard shells are supported by the first and second substrates, respectively. The shells cooperate to form a mold cavity therebetween. Each shell is less than approximately 10 mm thick in order to provide a low thermal mass and high thermal responsiveness.

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 three-dimensional electroformed shell for a mold consists of a three-dimensional thin-walled body, and an electroformed coating deposited on it. The coating may, or may not close the base holes of the thin-walled body completely. If it does not close the base holes completely, the shell has a multiplicity of apertures. A process for manufacturing the shell is also disclosed.

Abstract: The tire mold having a surface 5 of open porosity which covers at least in art certain of the molding surfaces 10 and 20 in order to assure the venting of the mold.

Abstract: A multilayered insulated mold structure for forming textured articles is disclosed. An insulation layer is deposited on the mold core and a multilayered skin layer is deposited on the insulation layer. The skin is formed of a plurality of sublayers, including a corrosion-resistant phosphorous-rich nickel region on the insulation layer acting as an etchant stop, and an non-corrosion resistant, or etchable, phosphorous-poor nickel region on the corrosion-resistant layer. The upper layer is uniformly textured by selective etching down to a depth terminating at the interface between the layers, but the insulation layer is protected. A method of molding uniformly textured articles is also disclosed, as is a method of making a mold suitable for producing uniformly textured articles and a method for making such a mold surface having bulk imperfections.

Abstract: Improved optical disks for information storage and holographic imaging, and optical lenses and reflective optical elements are among the difficult-to-mold thermoplastic products which require precision replication of the molding surfaces, in micro detail. By heating (with circulating heat transfer fluids supplied by a hot side reservoir) these mold surfaces to a temperature setpoint sufficiently high to retard solidification and premature viscoelastic skinning of the molten thermoplastic injected into the mold cavity, superior quality molded surfaces can be formed by the plastic, which is then rapidly cooled to solidification (by circulating heat transfer fluids supplied from a cold side reservoir).

Abstract: A coated tool or instrument has a wear-resistant hard coating (7) which is preferably titanium nitride for working organic material which is disposed on a separating layer (9) applied on a basic body (3). The separating layer (9) comprises a ceramic electrically non-conducting material. Such a material is preferably an oxide, nitride or oxynitride of silicon. The separating layer (9) protects the basic body (3) of the tool or instrument of e.g. a non-corrosion resistant steel. During the coating of the basic body (3) with the ceramic material, a pulsating dc voltage is applied to the basic body (3) or its holders. The pulse height is changed during the vapor deposition from high negative values to low negative values.

Abstract: There is provided a cast molding die for an information recording medium, having a mold surface with a prescribed unevenness pattern including a projection; wherein the projection has at least one pair of opposite side slopes each of which forms an acute angle with respect to the extension of the mold surface. By using the cast molding die having the above-mentioned projection with a three-dimensional shape, a defect such as lack in the resultant information recording medium is prevented.

Abstract: A bimetallic cylinder of steel having an alloy inlay which includes chromium boride in a matrix of iron alloy containing carbon, silicon, nickel and copper. The chromium boride imparts wear resistance to the inlay and relatively high contents of chromium, nickel and silicon and the presence of molybdenum and copper in the alloy make it resistant to corrosion. The cylinder is useful for injection molding and extrusion of plastics.

Abstract: A multilayered insulated mold structure is provided. An insulation layer provided on each of the mold cores retains heat at the molding surface, thereby increasing surface quality of the finished part. The insulating layer has a varying density across its thickness so as to have a low density center region and high density surface regions. By having a relatively low denisty, the center region of the insulating layer has a low thermal conductivity. Thus, the insulating layer may be made from the same material as the core and still have an acceptable insulating value. The use of the same material for adjacent layers reduces the potential of delamination of the layers. The multilayered mold is compatible with passive or active heating of the molding surface.

Abstract: A multilayer mold for use in blow molding parts within short cycle times is provided. The multilayer mold has a hard skin layer, an insulating layer and a base containing cooling means. The transient temperature increase of the skin layer of the mold as a hot parison contacts the mold is used to produce smooth surfaces on parts since the skin layer remains hot during parison inflation.

Abstract: A sintering device includes separable mould walls which together define a mould cavity and a mould core which is positioned within the cavity to define an undercut mould surface. The core includes a hollow frusto-pyramidal central support formed with guideways and a plurality of core segments mounted for slidable movement within the guideways whereby the core is radially expandable and contractable. The segments include a plurality of arc-surface segments alternating with trapezoidal segments. The mould walls and the core include passages for introducing steam and air into the cavity. The passages of the core place the hollow interior of the central support in communication with the mould cavity.

Abstract: A method of producing cylindrical objects with one or more lobes in which the bore surfaces are completely protected by a surface layer of abrasion resistant and/or corrosion resistant alloy and which protective layer is free of any contamination by the metal of the substrate. A hard, wear resistant, and corrosion resistant nickel-based alloy is especially suitable as lining material for surface of cylindrical products, such as housings or shells used in extrusion and injection molding devices for processing halogenated resins or rubbers. The alloys will preferably also contain 0.5 to 5% silicon and 1 to 4% boron. Also disclosed is a method of producing cylindrical objects with one or more lobes in which the bore surfaces are completely protected by a surface layer of abrasion resistant and/or corrosion resistant alloy, such as the above-described metal-based alloy.

Abstract: A forming mold main body made of a first platelike member defining a forming mold surface of a predetermined shape and a second platelike member joined air-tightly at least at circumferential portions to the first member to define therebetween a jacket for heating or cooling medium. Plural spacers can be disposed between the two platelike members.

Abstract: A mold for press-molding glass elements comprising a base member made of a super hard alloy or a cermet; at least one intermediate layer made of a nitride, a carbide, an oxide or a metal, provided on the base member; and a noble metal layer provided on the intermediate layer for forming a mold surface. An active metal contained in the base member is prevented from diffusing to the mold surface by the presence of the intermediate layer.

Abstract: A novel coating (34) is provided on a member (24) which may be part of a mold (24). Plastic articles (10) which are made by injection molding within such a mold (24) can have a very smooth surface by replication of the surface coating (34). This allows the production of so-called rigid discs with a plastic core in place of the present day aluminum cores.

Abstract: A glass optical element is directly press-molded by a method using a noble mold. The mold comprises a base material and a press surface film formed on the base material. The press surface film is an Ir film, or a Ru film, or an alloy film comprising Ir and at least a member selected from the group consisting of Pt, Re, Os, Rh and Ru, or an alloy film comprising Ru and at least a member selected from the group consisting of Pt, Re, Os and Rh.

Abstract: Disclosed is a molding method for producing an optical glass element which comprises the steps of preparing a mold coated with a thin film of a noble metal alloy, and molding optical glass into the form of an optical glass element by using the mold while applying heat and pressure to the optical glass. Further disclosed is such a mold that is coated with a thin film of a noble metal alloy, for producing an optical glass element.

Abstract: An ingot mold with mold wall and stool shields and the method of installing the mold wall and stool shields to the ingot mold and stoll. The mold wall shield comprises at least two portions connected by a bend. The mold wall shield and the stool shield can be multi-layered to provide a thin envelope or layer of air between the parallel layers. The shields are nailed to the mold or stool by an explosion actuated hammer. The mold wall shield is installed with the bend near the intersection between the mold and the stool. The shields are made of similar material to that being cast and melt due to the heat of the molten metal in the mold.

Abstract: A method of producing cast metal tooling, especially injection molds or dies, characterized by the steps of making a thin walled, investment cast shell which defines the functional cavity surface of the tooling, and casting a suitable backing metal against the shell to form a composite die or mold structure.

Abstract: In a continuous casting mold of a copper alloy havng a nickel layer plated on the mold cavity surface, wherein an alloy layer of nickel containing one of Co, Fe and Mn and 3-5 mm thickness replaces the Ni layer.

Abstract: A mold for manufacturing silicone contact lenses is provided. The mold comprises a male section and a female section plated with chromium or nickel which when joined together come into contact with each other only at a portion at which the mold surface of one section becomes continuous with that of the other section to define a cavity therebetween. The contact between both sections is not in a flat-to-flat fashion but in a line or edge-to-edge fashion so that a contact lens whose surface and edge are completely freed from flashes or irregularities can be obtained. Further, with the use of chromium or nickel plated mold of the present invention, a contact lens of excellent quality can be obtained from a silicone resin which is affinitive to chromium and nickel.

Abstract: A mold for vacuum forming plastic sheet and the like and a method of making the mold. A relatively thin mold shell provides a forming surface through which small apertures open to exhaust air to vacuum form a heat-softened plastic sheet. Small manifold conduits behind the forming surface connect the apertures to a source of vacuum. The mold area subtended by the manifold conduits is substantially less than the area of the entire forming surface, thereby substantially limiting the force exerted upon the forming surface by the pressure differential created during vacuum forming of a plastic sheet. The mold is preferably made by electroforming a metallic shell on a pattern, and is apertured in a desired pattern. Filaments are advantageously used to form the apertures during electroforming. A low melting point material is applied to the back of the shell in a manifold pattern to connect the apertures and a metallic layer is electroformed to the back of the shell.

Abstract: A copper or copper alloy mold for continuously casting steel is characterized in that the mold has a first layer formed on its interior surface and comprising at least one of nickel and cobalt and a second layer formed on the first layer and containing at least one of nickel and cobalt as a main component and at least one of phosphorus and boron.