BRPI0609821A2 - tempering mold - Google Patents

Abstract

TEMPLATE TEMPLATE. The present invention relates to a tempering mold (22) including an inner cavity and a liner (20, 21) over the inner cavity. The coating includes a plurality of particles (20), such as metallic coated particles, superabrasive particles, or metallic particles in a metal matrix.

Description

"TEMPLATE TEMPLATE"

Invention History

In a modern manufacturing process used to produce various types of light bulbs, a high speed running machine is used. The primary component of wear on belt machines and similar types of high speed bulb making machines is the tempera mold. Although there is typically no direct contact between the glass and the inner surface of the mold, the combination of hot flow and heat deteriorates the mold surface.

Much time and labor is required to apply a sacrificial coating to a tempering mold. As in Figure 1A, a mold section 10 may include a housing 11 and an interior cavity section 12. The inner cavity section may include one or more openings 13 and a moisture retaining coating and minimize glass adhesion to the mold cavity. This coating can be done by applying a resin, such as flaxseed oil, to the bare surface of the interior of the mold. With the oil still damp, a properly sized cork powder can be sprayed onto the oil layer. After the oil has dried, the excess of cork is removed from the coating. The molds are kept in an oven at 400 ° F for 3 to 4 hours. The resulting coating has a rough texture and is highly convoluted with a large surface area suitable for fixing or retaining water. Figures 1B and 1C show microphotographs of the prior art tempera coating or mold at 15X and 150X magnifications respectively.

Although a prior art cork coating works well, it typically only lasts about 2 to 5 days under continuous production.

The present specification solves some of these problems.

Summary of the Invention

In one embodiment, the specification relates to a tempering mold which may include an inner cavity and a coating over this inner cavity, where a coating may include a plurality of metal coated departments. In one embodiment, the particles may include superabrasive particles, and the metal may include titanium, chrome, nickel, cobalt, copper, tantalum, iron, or silver. In one embodiment, the particles comprise graphite particles. In various embodiments, the metallic coated particles could also be coated with superabrasive material. In another embodiment, the particles may include graphite with a superabrasive coating material, and the metal may include copper or nickel. The coating may have an overall thickness of about 50 µm to about 500 µm, and retain a volume of water of about 40 mm3 to about 90 mm3 per mm3 of the coating.

In an alternative embodiment, the coating may include a plurality of superabrasive particles in a metal matrix. Superabrasive particles may have a diameter of from about 0.1 µm to about 1.0 µm, and the metal may include nickel, chromium, copper, cobalt, or their alloys. The coating may have a thickness of from about 50 µm to about 500 µm. In another embodiment, the coating may include a plurality of metal particles in a metal matrix, where such particles may include copper, steel, brass, bronze, or cobalt.

Brief Description of the Drawings

The patent or patent application contains at least one color drawing, and copies with color drawing (s) will be provided upon payment.

Figure 1A shows an exemplary light bulb tempera mold;

Figure 1B is a photomicrograph of a 15X enlarged prior art coating;

Figure 1C is a photomicrograph of a 150X enlarged prior art coating; Figure 2 shows exemplary elements of various coatings of the present invention;

Figure 3 shows exemplary alternative coating elements of the present invention;

Figure 4 shows a third embodiment of a coating of the present invention;

Figure 5 shows a fourth embodiment of a coating of the present invention;

Figure 6 shows a fifth embodiment of the present invention;

Figure 7 shows the initial water retention of various coatings;

Figure 8 is a microscopic image of a titanium coated diamond coating of the invention;

Figure 9 is a microscopic image of the graphite nickel coated composite particle coating of the present invention, provided that a textured mold assembly surface is applied;

Figure 10 is a microscopic image of the nickel-graphite coated composite particle coating of the present invention, provided that a textured mold assembly surface is applied;

Figure 11 is a microscopic image of the nickel graphite coating of the present invention;

Figure 12 is a microphotographic image of a nickel-graphite coated composite particle coating of the present invention.

Detailed Description

A superabrasive material is any material with Vickers hardness greater than about 300 / mm3, or optionally greater than about 3000 / mm3. It has been found that in various configurations the application of superabrasive composite materials, such as those using diamond or cubic boron nitride (cBN) to certain components in a glass bulb manufacturing process can reduce wear, maintenance downtime, total cost of fabrication while simultaneously Improves energy efficiency maintains critical equipment tolerances most effectively. In particular, it has been found that diamond or cBN compounds can provide a corrosion resistant coating and are more durable and capable of retaining a high amount of water in the components, such as in bulb temper molds. This allows the tempering molds to be coated with a durable coating and allows them to perform more consistently and for a longer time in bulb manufacturing processes. Various types of composite coatings including, but not limited to, superabrasive coatings, which will be described in the further development of this specification, to provide improved component performance. Based on this specification, those skilled in the art should recognize that other superabrasive coatings could also be used.

In a first embodiment, as shown in Figure 2, a layer comprising cBN and / or diamond20 and metal 21 particles may be applied to the inner surface of a tempering mold 22 using either electrolytic or non-electric methods. The coating may be highly resistant to abrasive wear, form a corrosion resistant surface and conducive to heat and electricity. Suitable coating methods can be found in U.S. Patent Nos. 4,997,686 and 5,114,517, for example, which are incorporated herein by reference in their entirety. Since the coating may be applied to a structural material such as steel, reinforced composites, ceramics, or plastics, the risk of catastrophic failure during service may be reduced. The life of the part can be extended because it is given a higher resistance to corrosion, erosion, abrasion to the coating. The diamond or cBN layer may have a larger diameter / thickness than the average size of a superabrasive particle, and the metal may include but not selecting the nickel, cobalt, copper, or alloys thereof. The average particle size of the superabrasive particles used may range from about 071 µm to about 50 µm at the maximum outside diameter, or optionally from 0.25 µm to about 1.0 µm. xm in diameter.

Other sizes are also possible. Preferably and optionally, the coating layer thicknesses range from about 50 µm to about 500 µm, or from about 100 µm to about 200 µm in various configurations.

In a second embodiment, as shown in Figure 3, a layer of copper or other metal particles 30 in a continuous metal matrix 31 may be co-deposited with tempering 32 using electrolytic or non-electric methods. This coating can be highly resistant to abrasive wear, form a rough, convoluted surface, conduct heat and electricity, and erect a significant amount of moisture on the surface. The life of the part can be extended as much as of a similar coating by using particulate particles. The softer coating may be even harder than cork, but without exposing the diamond glass component, which can potentially create cracks. The metal particle layer may include, but is not limited to, copper, steel, bronze, brass, or cobalt and have a thickness of at least one particle. The continuous metal matrix may include, but is not limited to, nickel and copper. As in the first embodiment, in the second embodiment preferably, but not necessarily, particle sizes range from about 0.1 µm to about 50 µm or range from about 0.25 µm to about 1.0 µm. Preferably, but not necessarily, the coating thicknesses range from about 50 µm to about 500 µm, or from about 100 to about 200 µm. In a third configuration, as shown in Figure 4, a layer of Coated cBN and / or diamond particles 40 in a metal matrix 41 may be applied to the inner surface of a tempering mold 42 using electrolytic or non-electric methods. Metal coatings 43 on the surface of cBN or diamond particles 40 which may include, but are not limited to, titanium, chrome, nickel, cobalt, copper, tantalum, iron, silver, or combinations of these, or multiple layers of any of the above elements. may allow the coating layer of the present invention to perform the desired function. The coating layer may be thicker than a superabrasive particle and the metal matrix may include, but is not limited to, nickel or copper. For example, preferably (but not necessarily), particle sizes and coating thicknesses may or may not cover the entire surface of the particles. Preferably, the metal coating has a maximum thickness less than the maximum diameter of the superabrasive particle. In a fourth configuration, as shown in Figure 5, a tempering mold interior cavity 51 may be coated with a layer of metallic coated graphite particles 50. The layer may be applied to a tempering mold 51 by hot spraying. Those skilled in the art will appreciate that other processes could be used to apply the layer. In addition, the metallic coating 52 on the particle includes, but is not limited to, nickel and copper. The metal-coated graphite department layer applied with this technique can be a relatively porous open structure capable of holding a considerable amount of water. In some embodiments, graphite particles 50 may range in the range from about 10 µm to about 50 µm. In another embodiment, the particles 50 may be available in sizes ranging from 50 to 150 µm. Other department sizes also being possible. The particle layer may have an overall thickness of about 0.001 to about 0.050 µm. Alternatively, the particle layer may have an overall thickness of from about 0.1 to about 500 µm, from about 50 to about 500 µm, from about 100 to about 200 µm, or other suitable sizes. The weight of the metal to graphite may be about 85% metal to 15% of graphite. In an alternate configuration, the weight percent of metal to graphite may be about 60% to 40%, respectively. 75% metal for about 25% graphite, or about 80% metal for about 20% graphite Other solid lubricants such as hexagonal boron nitride (hBN) talc, MoS2, or other materials could be used instead. In addition to the vaporous nature of metal-graphite coatings, coated graphite particles can also provide an un-wetted surface against molten glass, which prevents the melt from sticking to the coating. before cooling.

In a fifth embodiment, as shown in Figure 6, a layer of metallic coated graphite particles 60 as described above may include an additional coating of a superabrasive material such as cubic boron nitride or diamond 61. An additional coating 61 may be applied to a tempering mold 63 to reinforce the metal-graphite coating62 and increase abrasion resistance. The composite coating 61 added to the graphite metal coating 62 may be thin, for example, about 1 µm to 25 µm thick, or about 2 µm to 10 µm, so that the overall porosity and water retention capacity of the graphite metal coating 62 are not substantially reduced. As the metal-graphite coating 62 has an open structure, optionally, the additional coating 61 uniformly coats all exposed metal-graphite coating 62. The composite overcoat 61 increases adhesion between the metal-graphite coating 62 and the graphite particle 60.

In a composite coating method using a non-electric process for co-depositing hard particles, such as superabrasive particles, such as silicon carbide, boron carbide, alumina, and other particles, the particles may be inert to the chemical where they are suspended. For example, diamond particles suspended in a non-electric coating bath may not self-catalyze to the nickel dissolved in the solution, and nickel may not settle on the diamond surface. When there is co-deposition of the nickel and diamond particles in this case, the resulting composite layer may be uniform and conform to the substrate to which the coating has been applied. For example, if a steel panel with roughness of about 0.1 p Ra is coated with a composite coating having diamond particles with a particle size of about 0.8 µm, the resulting roughness of the coating will be about 0, 8 / xm.

However, when a metal layer is deposited on the surface of the graphite particles, this layer may become self-catalytic to nickel or another metal in a coating bath. Thin layers of titanium and / or chromium may be deposited on the decBN or diamond particles by chemical vapor deposition (CVD). Optionally, the coating on each particle may comprise less than 50% of the particle diameter. In various configurations, the coating thicknesses may be less than about 20%, 10%, 5% or even 1% of the overall particle size. Those skilled in the art will realize that other techniques could equally be used. In this case, when finely divided particles including a metallic coating such as titanium or chrome are added to the coating bath, the surface area of the metallic coating may be significantly larger than that normally recommended for stable operation of the bath. When the bath is properly activated, deposition will occur. Self-catalytic coating-metal solution, the metal in the solution begins the high-speed coating process, primarily because of the large surface area of the metal that may be coated on the particles. Metal-coated particles may get trapped on the surface of the substrate that is being coated, but because of the rapid metal plating of the coating solution, the coating layer can be formed quickly, and have many nodules, which give the appearance of the resin and cork surface. The resulting surface coating components may have a surface roughness of about 40 µm, a peak-to-peak distance of about 250 µm, and an average peak-to-distance of about 200 µm, and the ability to retain surface moisture. ± 50% over these distances. The overall thickness of the composite coating in this case may be in the order of about 200 to about 500 µm, although other sizes are also possible, thicker than composite coatings made of uncoated particles. It is also important to note that the nodular component given by the rapid composition of the coating bath may have a diameter in the order of about 50 to about 30 µm. Here, other sizes are also possible. As the metallic coating sticks to the mold substrate, the composite coating It can be highly resistant to abrasive wear. The coating may be applied to a structural material such as steel, reinforced composites, ceramics, or plastics and, therefore, reduce the risk of catastrophic failure in service. The described coating provides adequate porosity and water retention characteristics. For example, in some embodiments, after immersion in water of a coated temper mold, the coated part may retain a water volume of about 0.4 mm3 to about 0.9 mm3per mm3 of the coating.

EXAMPLES

The primary function of a light bulb temper mold is to retain moisture on the surface and pores of the coating. The effectiveness of a tempera mold is directly proportional to the amount of water retan coating. A technique has been developed for measuring moisture retention of coatings in diamond composite coated (CDC) shoulder boards. A series of laboratory tests were performed where small steel panels (2 in. By 3 in.) Were coated with CDC-8, CDC-15, CDC-Ti (as will be described in detail) and the above cork coating. 8, CDC-15, CDC-Ti were applied to steel panels using techniques based on US Patent No. RE 33,767, the specification of which is incorporated by reference using the technology described in U.S. Pat. No. 6,306,466, the specification of which is incorporated herein by reference. The CDC-8 coating was made of 8 µm diamond particles in a non-electric nickel phosphor matrix, resulting in a coating thickness of approximately 0.002 µm. The CDC-15 coating was made of 15 µm diamond particles in a non-electric phosphor nickel matrix, resulting in a coating thickness of about 0.002 µm. The CDC-Ti coating was made of 8 µm diamond particles having a titanium coating on the outer layer of the non-electric phosphor nickel composite coating, resulting in a composite coating thickness greater than 0.004 / xm.

Example 1

A cork / resin panel was weighed on a scale, which was then reset, then the panel was dipped to a common level in a beaker. Excess water was removed by shaking and the panel immediately weighed and the weight of moisture retained noted. The panel was then standing for one minute and then weighed. The procedure - standing and weighing - was repeated for seven minutes. As shown in figure 7, the cork lining, which is the standard tempering lining, retained 0.48 grams of water.

One panel was coated with a diamond composite coating made of 8 / xm (CDC-8) and 15 / xm (CDC-15) diamonds and weighed on a scale, which was then made, and then the panel was dipped in water at a common level in a beaker. Excess water was removed by shaking, and the panel immediately weighed, and the weight of the moisture retained noted. The panel was then placed for a minute and then weighed. The procedure - standing and weighing - was repeated for seventy minutes. As shown in Figure 7, the diamond-composite coating on the CDC-8 and CDC-15 diamond-containing panels retained about 0.10 grams of water.

Example 3

A diamond-made 8 / xm diamond-coated composite panel coated with a fine titanium (30 wt%) was weighed on a scale, then zeroed, then the panel was dipped to a common level in a beaker. . Excess water was removed by shaking the panel immediately standing up for a minute and then weighing. The procedure - standing and weighing - was repeated for seventy minutes. Figure 8 shows a microscopic image of a titanium coated diamond coating of the present invention. As shown in Figure 7, the diamond-coated coating having titanium-coated diamond particles (CDC-Ti) retains approximately 0.26 grams of water.

Example 4

In a production tape machine used to produce conventional incandescent light bulbs, the main component of interest in testing is the hot melt mold. In the test, two new mold assemblies were obtained from the mold inventory, similar to those of a production burst. The test included applying a diamond composite coating to a demolition assembly. This coating used 8 µm diamonds at a diamond volume concentration of approximately 40% and a thickness of 0.001 inches (25 µm). For the other mold assembly, the inner surface of the mold was laser etched primarily to give textures similar to that of After the mold has been etched, a diamond composite coating was applied to that which was used in the first mold assembly. The resulting surface of the mold assembly 1 is shown in Figure 9, and the resulting surface of the mold assembly 2 shown in figure 10.

Example 5

Steel panels were coated with a nickel-graphite coating. Prior to coating, the surface of the panels was wiped with alcohol to remove grease, then blasted with # 30 aluminum oxide powder to produce a certain surface roughness. A base coat of the Metco 450 hot-spray coating at approximately 0.02 inches for the nickel-graphite bed glue. Nickel graphite powder used was 307NS from Sulzer Metco. This powder was applied using a Type 5P spray gun using oxyacetylene gas with the parameters recommended by Sulzer Metco. The nickel graphite layer was applied at 0.004 inches and 0.015 inches. Figure 15 is a microscopic image of the nickel graphite coating on a steel panel. A retention test was performed on the nickel-graphite panel and the total amount of water retained in the coating was measured. As shown in Figure 7, the amount of water covered by the one-sided (hot spraya) coated steel panel was approximately 0.72 grams.

Example 6

A steel panel of example 5 was further processed by applying a composite coating as described in example 2. The composite coating here used a 2 µm diamond particle in a non-electric deniquel matrix. The coating thickness was about 10 µm. As shown in Figure 12, the graphite particle matrix matrix of nickel and diamond are clearly seen. Water retention and abrasion tests have also been performed on this panel and the test panels of previous examples. The water retention test results are shown in Figure 7 (TS + CDC), giving the panel retained about 0.38 grams of water. While the present invention has provided considerable detail with reference to preferred embodiments, other variations will also be appreciated. possible. Therefore, the spirit and scope of the appended claims are not limited to the description given and preferred versions contained in this specification.

Claims (19)

1.- Temper mold, characterized by the fact that it comprises: an inner cavity; and - a coating over the inner cavity, wherein the coating comprises a plurality of metallic coated particles, the metallic coated particles in turn being coated with a superabrasive material, the metallic coated particles being coated with a superabrasive decomposed coating. Temper mold according to Claim 1, characterized in that the particles comprise superabrasive particles. Temper mold according to Claim 1, characterized in that the coating comprises superabrasive particles in a metal matrix. Temper mold according to Claim 1, characterized in that the metal comprises titanium, chrome, nickel, cobalt, copper, tantalum, iron, or silver. Temper mold according to Claim 1, characterized in that the particles comprise graphite particles. Temper mold according to Claim 1, characterized in that the coating retains a volume of water of about 0.4 mm3 to about 0.9 mm3 per mm3 of the coating. Temper mold according to Claim 1, characterized in that the particles comprise graphite, the metal comprises copper or nickel, and the particles are also coated with a superabrasive material. Temper mold according to Claim 3, characterized in that the metal matrix comprises nickel, chromium, copper, cobalt or their alloys. Temper mold according to Claim 1, characterized in that the coating has an overall thickness of from about 50 to about 500 µm. Temper mold according to Claim 1, characterized in that the particles comprise graphite, hexagonal boron nitride, talc, MoS2, and the particles comprise about 10% to about 80% by weight of the coating. 11.- Temper mold, characterized by the fact that it comprises: an inner cavity; and a coating on the inner cavity, wherein the coating comprises a plurality of superabrasive particles in a metal matrix, wherein the particles and metal matrix are coated with a superabrasive composite. Temper mold according to Claim 11, characterized in that the superabrasive particles have a diameter of from about 0.1 µm to about 50 µm. Tempering mold according to Claim 11, characterized in that the metal comprises nickel, chromium, copper, cobalt or alloys thereof. Temper mold according to Claim 11, characterized in that the coating has a thickness of from about 50 µm to about 500 µm. Temper mold according to Claim 11, characterized in that the particles comprise cubic boron nitride particles. 16. - Temper mold, characterized by the fact that it comprises: an inner cavity; and - a coating over the inner cavity, wherein the coating comprises a plurality of metal particles in a metal matrix, the particles and the metal matrix being coated with a superabrasive composite. Temper mold according to Claim 16, characterized in that the metal particles comprise copper, steel, brass, bronze or cobalt. Temper mold according to Claim 16, characterized in that the metal matrix comprises nickel, chromium, copper, cobalt or alloys thereof. 19. The mold of claim 16 wherein the metal particles comprise a diameter of from about 0.1 µm to about -50 µm.