US4590031A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Molding tool and method
Assignee: Bodycote Metallurgical Coatings Inc
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Filing: 1984-04-06
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Granted: 1986-05-20
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Expires: 2004-04-06
Abstract
Abstract A coating and method of depositing it is provided. The wear resistant coating comprises a thin layer of disordered boron and carbon applied to a substrate. The coating has good adherence and provides good resistance to wear so that it is useful as a tool coating. In a more specific embodiment, the coating is disordered boron carbide. The coating can have a high gloss and can also be used as a decorative coating. The coating can be made by sputtering boron and carbon onto a substrate. A bias voltage may be applied to the substrate during sputtering. In accordance with one embodiment, the disordered boron and carbon coating is of a composition B x C 1-x where x is from about 0.60 to about 0.90. In accordance with another embodiment, an improved molding tool is provided that includes a disordered carbon coating on at least a portion of the working surface of the molding tool. The coating provides improved release characteristics, longer tool life and results in molded articles having smoother finishes and improved detail.
Inventors
- 👤 Erwin Eichen
- 👤 James D. Flasck
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 16:52
CPC Classifications
C; C23; C23C; C23C14/00; C23C14/06; C23C14/14; C23C14/16; C23C14/0635; A; A61; A61C; A61C3/00; A61C3/02; C23C30/00
Claims Analysis
Total Claims: 36
Claim 1
Independent Claim
52 words
A mold comprising: (a) a hollow form defining a working surface for forming a moldable or castable material into a predetermined shape; and (b) a thin coating over at least a portion of the working surface for contact with said material during molding, said coating consisting essentially of disordered boron and carbon.
Claim 2
Dependent Claim
52 words
A mold comprising: (a) a hollow form defining a working surface for forming a moldable or castable material into a predetermined shape; and (b) a thin coating over at least a portion of the working surface for contact with said material during molding, said coating consisting essentially of disordered boron and carbon.
Claim 3
Dependent Claim
14 words
The mold of claim 1 wherein said coating is formed by dc magnetron sputtering.
Claim 4
Dependent Claim
18 words
The mold of claim 1 wherein at least a portion of the coating is formed by bias sputtering.
Claim 5
Dependent Claim
28 words
The mold of claim 1 wherein said coating is formed by dc magnetron sputtering with a bias voltage being utilized during at least a portion of said sputtering.
Claim 6
Dependent Claim
14 words
The mold of claim 1 wherein said disordered boron and carbon comprises amorphous material.
Claim 7
Dependent Claim
14 words
The mold of claim 1 wherein said disordered boron and carbon comprises polycrystalline material.
Claim 8
Dependent Claim
14 words
The mold of claim 1 wherein said disordered boron and carbon comprises microcrystalline material.
Claim 9
Dependent Claim
28 words
The mold of claim 1 wherein said disordered boron and carbon material comprises at least one phase selected from the group consisting of amorphous, microcrystalline and polycrystalline phases.
Claim 10
Dependent Claim
13 words
The mold of claim 1 wherein said boron and carbon is substantially amorphous.
Claim 11
Dependent Claim
12 words
The mold of claim 1 wherein said coating comprises disordered boron carbide.
Claim 12
Dependent Claim
29 words
The mold of claim 1 wherein said coating has a composition on an atomic basis of B x C 1-x where x is from about 0.60 to about 0.90.
Claim 13
Dependent Claim
22 words
The mold of claim 1 wherein the thickness of the coating is in the range from about 0.20 to about 8 micrometers.
Claim 14
Dependent Claim
24 words
The mold of claim 1 wherein the thickness of said coating is in the range of from about 0.080 micrometers to about 5.0 micrometers.
Claim 15
Dependent Claim
15 words
The mold of claim 1 wherein the thickness of said coating is about 2.5 micrometers.
Claim 16
Dependent Claim
18 words
The mold of claim 1 wherein said coating is over substantially the entire working surface of the mold.
Claim 17
Dependent Claim
12 words
The mold of claim 1 wherein said hollow form comprises cast iron.
Claim 18
Independent Claim
103 words
A method of molding an article comprising: (a) providing a mold having a working surface that defines a predetermined shape, said working surface having a coating for contact with material to be molded during molding, said coating formed by sputtering while maintaining said working surface at a temperature permitting the formation of disordered boron and carbon and consisting essentially of disordered boron and said carbon, said coating over at least a portion of said working surface; (b) placing a moldable material in said mold and forming said moldable material into the desired shape; and (c) thereafter releasing the moldable material from the mold.
Claim 19
Independent Claim
103 words
A method of molding an article comprising: (a) providing a mold having a working surface that defines a predetermined shape, said working surface having a coating for contact with material to be molded during molding, said coating formed by sputtering while maintaining said working surface at a temperature permitting the formation of disordered boron and carbon and consisting essentially of disordered boron and said carbon, said coating over at least a portion of said working surface; (b) placing a moldable material in said mold and forming said moldable material into the desired shape; and (c) thereafter releasing the moldable material from the mold.
Claim 20
Dependent Claim
11 words
The method of claim 17 wherein the moldable material is glass.
Claim 21
Dependent Claim
25 words
The method of claim 18 wherein the glass is molded at elevated temperature, said elevated temperature being lower than the crystallization temperature of said coating.
Claim 22
Dependent Claim
15 words
The method of claim 19 wherein said elevated temperature is less than about 1000° C.
Claim 23
Dependent Claim
14 words
The method of claim 17 wherein said coating is formed by dc magnetron sputtering.
Claim 24
Dependent Claim
18 words
The method of claim 17 wherein at least a portion of the coating is formed by bias sputtering.
Claim 25
Dependent Claim
28 words
The method of claim 18 wherein said coating is formed by dc magnetron sputtering with a bias voltage being utilized during at least a portion of said sputtering.
Claim 26
Dependent Claim
14 words
The method of claim 17 wherein said disordered boron and carbon comprises amorphous material.
Claim 27
Dependent Claim
14 words
The method of claim 17 wherein said disordered boron and carbon comprises polycrystalline material.
Claim 28
Dependent Claim
14 words
The method of claim 17 wherein said disordered boron and carbon comprises microcrystalline material.
Claim 29
Dependent Claim
28 words
The method of claim 17 wherein said disordered boron and carbon material comprises at least one phase selected from the group consisting of amorphous, microcrystalline and polycrystalline phases.
Claim 30
Dependent Claim
13 words
The method of claim 17 wherein said boron and carbon is substantially amorphous.
Claim 31
Dependent Claim
12 words
The method of claim 17 wherein said coating comprises disordered boron carbide.
Claim 32
Dependent Claim
29 words
The method of claim 17 wherein said coating has a composition on an atomic basis of B x C 1-x where x is from about 0.60 to about 0.90.
Claim 33
Dependent Claim
22 words
The method of claim 17 wherein the thickness of the coating is in the range from about 0.20 to about 8 micrometers.
Claim 34
Dependent Claim
23 words
The method of claim 17 wherein the thickness of the coating is in the range of from about 0.080 to about 5.0 micrometers.
Claim 35
Dependent Claim
18 words
The method of claim 17 wherein said coating is over substantially the entire working surface of the mold.
Claim 36
Dependent Claim
12 words
The mold of claim 1 wherein said coating is formed by sputtering.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-05-19 | 1989-11-18 | 1990-05-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-05-19 | 1993-11-18 | 1994-05-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-05-19 | 1997-11-18 | 1998-05-20 | $7700.00 | Window Closed / Lapsed |