Patent Application
20060150684
The present invention relates to a mold for molding glass articles, and more particularly relates to a composite mold and a method for making the mold.
Glass optical articles, such as aspheric lenses, ball-shaped lenses, prisms, etc. are generally made by a direct press-molding process using a mold. The glass optical articles obtained by the direct press-molding method advantageously do not need to undergo further processing, such as a polishing process. Accordingly, the manufacturing efficiency can be greatly increased. However, the mold used in the direct press-molding method has to satisfy certain critical requirements such as high chemical stability, resistance to heat shock, good mechanical strength, and good surface smoothness.
Several criteria that should be considered in choosing the material for making the mold are listed below:
In earlier years, the mold was usually made of stainless steel or a heat resistant metallic alloy. However, such mold typically has the following defects. Sizes of crystal grains of the mold material gradually become larger and larger over a period of time of usage, whereby the surface of the mold becomes more and more rough. In addition, the mold material is prone to being oxidized at high temperatures. Furthermore, the glass material tends to adhere to the molding surface of the mold.
Therefore, non-metallic materials and super hard metallic alloys have been developed for making molds. Such materials and alloys include silicon carbide (SiC), silicon nitride (Si3N4), titanium carbide (TiC), tungsten carbide (WC), and a tungsten carbide-cobalt (WC—Co) metallic alloy. However, SiC, Si3N4 and TiC are ultrahard ceramic materials. It is difficult to form such materials into a desired shape, especially an aspheric shape, with high precision. Further, WC and a WC—Co alloy are liable to be oxidized at high temperatures. All in all, these materials are not suitable for making high-precision molds.
Thus, a composite mold comprising a mold base and a protective film formed thereon has been developed. The mold base is generally made of a carbide material or a hard metallic alloy. The protective film is usually formed on a molding surface of the mold base.
Typically, the mold base of the composite mold is made of a hard metallic alloy, a carbide ceramic, or a metallic ceramic. The protective film of the composite mold is formed of a material selected from the group consisting of iridium (Ir), ruthenium (Ru), an alloy of Ir, platinum (Pt), rhenium (Re), osmium (Os), rhodium (Rh), and an alloy of Ru, Pt, Re, Os and Rh.
However, the mold base of the such composite mold has an unduly high hardness. Therefore a molding surface of the composite mold has to be machined by a diamond cutting tool, and the process for making the mold is unduly complex. In addition, the surface smoothness of the mold is relatively low, which may impair the workpiece release performance.
Therefore, a mold with good workpiece release performance and a simple method for making such a mold are desired.
A composite mold comprises a porous mold base and a lubricant filled in the porous mold base. The porous mold base has a first portion comprised of a sintered material formed by sintering noble metal particles and tungsten carbide particles. A molding surface of the porous mold base is defined on the first portion.
Preferably, the porous mold base further has a second portion. The second portion of the porous mold base is integrally formed with the first portion, and is located distal from the molding surface. The second portion of the porous mold base is made of a sintered material formed by sintering tungsten carbide particles. Alternatively, the second portion, like the first portion, is made of a sintered material formed by sintering noble metal particles and tungsten carbide particles.
A percentage by weight of the noble metal particles in the sintered material is generally configured to be in the range from 1% to 25%, and preferably in the range from 1% to 13%. The noble metal particles may be selected from the group consisting of Pt, Re, PtmRhn alloy, RexIry alloy, and PtmIrn alloy; wherein, x is in the range from 0.25 to 0.55, y is in the range from 0.45 to 0.75, and m and n satisfy the following conditions: m+n=100, and 10<m<90. The lubricant may be selected from the group consisting of mineral oil, animal oil, and vegetable oil.
A method for making a composite mold comprises the steps of: providing a first mold having a desired shape; placing a mixture of noble metal particles and tungsten carbide particles into the first mold; forming a porous mold base having a molding surface by sintering the mixture of noble metal particles and tungsten carbide particles; and filling the porous mold base with a lubricant by immersing the porous mold base in the lubricant. The first mold is made of a hard metallic alloy. A percentage by weight of the noble metal particles in the sintered material is generally configured to be in the range from 1% to 25%, and preferably in the range from 1% to 13%. The particle sizes of the noble metal particles and tungsten carbide particles are in the range from 1 nm to 100 nm. The noble metal particles may be selected from the group consisting of Pt, Re, PtmRhn alloy, RexIry alloy, and PtmIrn alloy; wherein, x is in the range from 0.25 to 0.55, y is in the range from 0.45 to 0.75, and m and n satisfy the following conditions: m+n=100, and 10<m<90. Preferably, the noble metal particles are placed adjacent a surface of the first mold corresponding to the molding surface of the porous mold base. The lubricant may be selected from the group consisting of mineral oil, animal oil, and vegetable oil.
The porous mold base has a composite structure made of a sintered material formed by sintering noble metal particles and tungsten carbide particles. Therefore the porous mold base has high hardness, and the molding surface of the porous mold base has good surface smoothness. Furthermore, due to the lubricant filled in the porous mold base, the following advantages are obtained. The lubricant can be released during a molding process, thereby forming a mold release agent on the molding surface. Thus a separate step of adding a mold release agent on the molding surface is not needed, and the molding process is simplified.
Other advantages and novel features will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
Many aspects of a composite mold and a method for making the same can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, the emphasis instead being placed upon clearly illustrating the principles of the composite mold and the method for making the same. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
The present invention is further described below including by reference to the figures.
Referring to
A percentage by weight of the noble metal particles 101 in the sintered material is generally configured to be in the range from 1% to 25%, and preferably in the range from 1% to 13%. The noble metal particles 101 may be selected from the group consisting of Pt, Re, PtmRhn alloy, RexIry alloy, and PtmIrn alloy; wherein, x is in the range from 0.25 to 0.55, y is in the range from 0.45 to 0.75, and m and n satisfy the following conditions: m+n=100, and 10<m<90. The lubricant 103 may be selected from the group consisting of mineral oil, animal oil, and vegetable oil, such as machine oil, organosilane, etc.
Referring to
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Referring to
The first mold is made of a hard metallic alloy. A percentage by weight of the noble metal particles 101 in the mixture is generally configured to be in the range from 1% to 25%, and preferably in the range from 1% to 13%. The particle sizes of the noble metal particles 101 and tungsten carbide particles 102 are in the range from 1 nm to 100 nm. The noble metal particles 101 may be selected from the group consisting of Pt, Re, PtmRhn alloy, RexIry alloy, and PtmIrn alloy; wherein, x is in the range from 0.25 to 0.55, y is in the range from 0.45 to 0.75, and m and n satisfy the following conditions: m+n=100, and 10<m<90. The lubricant 103 may be selected from the group consisting of mineral oil, animal oil, and vegetable oil, such as machine oil, organosilane, etc.
Referring to
The porous mold base of the composite mold has characteristics of high hardness and high mechanical strength, and ability to endure stresses at high temperatures. Because the porous mold base is formed of noble metal materials, the molding surface has good surface smoothness and good workpiece release performance. This means that a production yield of glass products having satisfactory quality can be improved. Furthermore, due to the lubricant filled in the porous mold base, the following advantages are obtained. The lubricant can be released during a molding process, thereby forming a mold release agent on the molding surface. Thus an additional step of adding a mold release agent on the molding surface is not needed, and the molding process is simplified.
It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 200510032759.9 | Jan 2005 | CN | national |
