Molds with coatings for high temperature use in shaping glass-based material

• US 10,435,325 B2
• Filed: 01/19/2017
• Issued: 10/08/2019
• Est. Priority Date: 01/20/2016
• Status: Expired due to Fees

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Hall, Jill Marie, Ukrainczyk, Ljerka
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US15/410,019
• Publication Number:
  US 20170203992A1
• Time in Patent Office: 992 Days
• CPC Class Codes: C03B 11/086 of coated dies use of materials as release or lubricating compositions C03B40/02
• CPC Class Codes: C03B 2215/11 Metals
• CPC Class Codes: C03B 2215/16 Metals or alloys, e.g. Ni-P, Ni-B, amorphous metals
• CPC Class Codes: C03B 2215/26 Mixtures of materials covered by more than one of the groups C03B2215/16 - C03B2215/24, e.g. C-SiC, Cr-Cr2O3, SIALON
• CPC Class Codes: C03B 2215/30 Intermediate layers, e.g. graded zone of base/top material
• CPC Class Codes: C03B 23/02 Re-forming glass sheets
• CPC Class Codes: C03B 23/0357 by suction without blowing, e.g. with vacuum or by venturi effect
• CPC Class Codes: C03B 40/00 Preventing adhesion between glass and glass or between glass and the means used to shape it , hold it or support it
• CPC Class Codes: C23C 14/0084 Producing gradient compositions
• CPC Class Codes: C23C 14/0641 Nitrides C23C14/0617 takes precedence
• CPC Class Codes: C23C 14/165 by cathodic sputtering
• CPC Class Codes: C23C 14/3464 using more than one target C23C14/56 takes precedence
• CPC Class Codes: C23C 14/3492 Variation of parameters during sputtering
• CPC Class Codes: Y02P 40/57 Improving the yield, e-g- reduction of reject rates

Abstract

A mold with a multi-layer coating is disclosed. The mold may include a mold body having an outer surface and a multi-layer coating disposed on the outer surface. The multi-layer coating may include a diffusion barrier layer disposed on the outer surface of the mold body and an intermetallic layer disposed on the diffusion barrier layer, wherein the intermetallic layer comprises Ti, Al, and an additional metal selected from the group consisting of Zr, Ta, Nb, Y, Mo, Hf, and combinations thereof. The diffusion barrier layer may restrict diffusion of metal from the mold body to the intermetallic layer.

Claims

1. A mold comprising:

a mold body having an outer surface and a multi-layer coating disposed on the outer surface, wherein the multi-layer coating comprises;

a diffusion barrier layer disposed on the outer surface of the mold body; and

an intermetallic layer disposed on the diffusion barrier layer, wherein the intermetallic layer comprises Ti, Al, and an additional metal selected from the group consisting of Zr, Ta, Nb, Y, Mo, Hf, and combinations thereof, wherein the intermetallic layer comprises a change in the additional metal content with a lower molar content of the additional metal in a portion of the intermetallic layer closest to the diffusion barrier layer and a higher molar content of the additional metal in a portion of the intermetallic layer farthest from the diffusion barrier layer, and

the diffusion barrier layer restricts diffusion of metal from the mold body to the intermetallic layer.

2. The mold of claim 1, further comprising a transition layer disposed between the diffusion barrier layer and the intermetallic layer, wherein the transition layer comprises a change in nitrogen content with a higher molar nitrogen content in a portion of the transition layer closest to the diffusion barrier layer and a lower molar nitrogen content in a portion of the transition layer closest to the intermetallic layer.

3. The mold of claim 1, further comprising an oxidized intermetallic layer disposed on the intermetallic layer.

4. The mold of claim 1, wherein the ratio of titanium molar content to aluminum molar content in the multi-layer coating is in a range from about 0.67 to about 1.

5. The mold of claim 4, wherein the ratio of titanium molar content to aluminum molar content in the multi-layer coating is about 1.

6. The mold of claim 4, wherein the ratio of titanium molar content to aluminum molar content in the multi-layer coating is greater than or equal to about 0.67 and less than about 1.

7. The mold of claim 1, wherein a sum of the molar concentration of titanium and aluminum in the intermetallic layer is greater than or equal to the molar concentration of the additional metal in the intermetallic layer.

8. The mold of claim 1, wherein a sum of the molar concentration of titanium and aluminum in the intermetallic layer is less than the molar concentration of the additional metal in the intermetallic layer.

9. The mold of claim 1, further comprising a metal layer comprising the additional metal of the intermetallic layer disposed on the intermetallic layer.

10. The mold of claim 9, wherein the intermetallic layer comprises a change in additional metal content with a lower molar content of the additional metal in a portion of the intermetallic layer closest to the diffusion barrier layer and a higher molar content of the additional metal in a portion of the intermetallic layer closest to the metal layer.

11. The mold of claim 9, further comprising an oxidized metal layer disposed on the metal layer.

12. The mold of claim 1, wherein the additional metal is zirconium.

13. The mold of claim 1, wherein the mold body is predominantly a metal selected from the group consisting of iron, nickel, chromium, copper, mixtures thereof, and alloys thereof.