CN101142145B - Wear-resistant and textured cladding for components used in the processing of glass bulbs - Google Patents

Abstract

The present disclosure relates to a quench mold (22) comprising an inner cavity and a cladding (20, 21) on the inner cavity. The coating (20) includes a plurality of particles, such as metal-coated particles, superabrasive particles, or metal particles in a metal matrix.

Description

Wear-resistant and textured cladding for components used in the processing of glass bulbs

CROSS REFERENCE TO RELATED APPLICATIONS : This application claims priority to and includes by reference US Provisional Patent Application No. 60/662,292, filed March 16, 2005.

background

High speed ribbon glass forming machines (ribbon machines) are used in modern processing techniques for manufacturing various types of light bulbs. On ribbon glass forming machines and similar types of high speed bulb making machines, the primary area or component of wear is the quench mold. Although there is usually no significant direct contact between the glass and the inner surface of the quenching mold, the combination of hot steam and heat degrades the surface texture of the mold.

烘烤3到4个小时。产生的覆层为非常粗糙并且高度褶皱的(convoluted)纹理，具有有益于维持或保持水的大的表面积。图1B和1C分别放大15倍和150倍图示灯泡淬火模上的所述现有技术覆层的显微照片。Applying the sacrificial coating to the quench mold takes a considerable amount of time and labor. As depicted in FIG. 1A , mold section 10 may include housing 11 and cavity section 12 . The interior profile may include one or more vents 13 and cladding to both retain moisture and reduce glass adhesion to the mold cavity. The cladding can be produced by applying a resin, such as linseed oil, to the bare steel surface within the mould. Tightlysized cork chips can be sprinkled over the oil layer while the oil is still wet. The oil was then allowed to air dry before excess cork was tapped off the cladding. The mold is placed into an oven and heated at 400

Bake for 3 to 4 hours. The resulting coating is a very rough and highly convoluted texture with a large surface area useful for retaining or retaining water. Figures IB and 1C illustrate photomicrographs of said prior art cladding on bulb quench molds at 15X and 150X magnifications, respectively.

While prior art cork cladding works well, such cladding typically lasts only 2 to 5 days in continuous production on a ribbon glass forming machine.

The disclosure contained herein is intended to address at least some of the above-mentioned problems.

Contents of the invention

In an embodiment, the present disclosure relates to a quench die that may include an inner cavity and a coating on the inner cavity, wherein the coating may include a plurality of metal-coated particles. In embodiments, the particles may include superabrasive particles and the metal may include titanium, chromium, nickel, cobalt, copper, tantalum, iron, or silver. In embodiments, the particles may include graphite particles. In various embodiments, the metal-coated particles can also be coated with a superabrasive material. In further embodiments, the particles may comprise graphite with a superabrasive coating and the metal may comprise copper or nickel. The coating may have an overall thickness of from about 50 microns to about 500 microns and may retain a volume of water having a volume of from about 40 mm3 to about 90 mm3 per mm3 of coating.

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

Description of drawings

This patent or application file contains at least one drawing executed in color. Copies of this patent or patent application with color drawing(s) will be provided by the Office upon request and upon payment of the necessary fee.

Figure 1A shows an exemplary glass bulb quench mold.

Figure IB illustrates a photomicrograph of a prior art coating at 15X magnification.

Figure 1C shows a photomicrograph of a prior art coating at 150X magnification.

Figure 2 illustrates exemplary elements of various coatings of the present disclosure.

Figure 3 illustrates exemplary elements of an alternative coating of the present disclosure.

Figure 4 shows a third embodiment of the coating of the present disclosure.

Figure 5 shows a fourth embodiment of the coating of the present disclosure.

Figure 6 shows a fifth embodiment of the coating of the present disclosure.

Figure 7 shows the initial water retention of various coatings.

Figure 8 illustrates a micrograph of a titanium-coated diamond coating of the present disclosure.

Figure 9 illustrates a micrograph of a composite, coated nickel-graphite particle coating of the present disclosure as applied to a mold set surface.

Figure 10 illustrates a micrograph of a composite, coated nickel-graphite particle coating of the present disclosure as applied to a textured mold surface.

Figure 11 illustrates a micrograph of a nickel-graphite coating of the present invention.

Figure 12 illustrates a micrograph of a composite, coated nickel-graphite particle coating of the present disclosure.

Detailed ways

A superabrasive material is any material having a Vickers hardness greater than about 3000 kg/mm3, or alternatively greater than about 3200 kg/mm3. In various embodiments, we have discovered that the application of superabrasive composites, such as those using diamond or cubic boron nitride (cBN), to certain components in the glass bulb manufacturing process can be achieved by more effectively maintaining critical Equipment tolerance (tolerance) to improve energy efficiency while reducing wear, maintenance shutdown (maintenance shutdown) and overall production costs. In particular, we have found that diamond or cBN composites can provide a durable and erosion resistant coating capable of maintaining high water levels for, for example, light bulb quench molds. This may allow the quench mold to be clad with a durable coating, and this may allow the quench mold to function more consistently and longer in the light bulb manufacturing process. Several types of composite coatings, including but not limited to superabrasive coatings, are described herein to provide improved component performance. Based on this disclosure, those skilled in the art will recognize that other superabrasive coatings can also be used.

As represented in Figure 2, in a first embodiment, a layer comprising diamond and/or cBN particles 20 and metal 21 may be plated onto the inner surface of the quench mold 22 using electroless or electrolytic methods. The coating can be highly wear resistant, can form a smooth surface, can be erosion resistant, and can be both thermally and electrically conductive. Suitable plating methods are generally described, for example, in US Patent Nos. 4,997,686 and 5,145,517, the disclosures of each of which are incorporated herein by reference in their entirety. Because the cladding can be applied to structural materials such as steel, reinforced composites, ceramics or plastics, catastrophic failures in use can be reduced. Part life may be extended due to the improved wear, corrosion and erosion resistance imparted by the coating. The layer of diamond or cBN may have a diameter thickness equal to or greater than the average size of one superabrasive grain, and the metal may include, but is not limited to, nickel, chromium, cobalt, or copper, or alloys thereof. The average particle size of the superabrasive particles used ranges from about 0.1 microns to 50 microns in maximum outer diameter, or alternatively ranges from about 0.25 microns to about 1.0 microns in diameter. Other sizes are possible. In various embodiments, preferred (though optional) coating thicknesses may range from about 50 microns to about 500 microns, or from 100 microns to about 200 microns.

As represented in FIG. 3, in a second embodiment, a layer of copper or other metal particles 30 in a continuous metal matrix 31 can be co-deposited to a quenching mold 32 using an electroless plating or electrolytic coating process. superior. This cladding can be highly resistant to abrasion, can form a rough and wrinkled surface, can resist erosion, can conduct both heat and electricity, and can retain a fair amount of surface moisture. Because the cladding can be applied to structural materials such as steel, reinforced composites, ceramics or plastics, catastrophic failures in use can be reduced. Part life may be extended due to the improved wear, corrosion and erosion resistance imparted by the coating. However, it may not be possible to extend the life as long as a similar coating using diamond particles. This softer cladding may still be harder than cork, but it may keep the glass part from being exposed to diamonds that could potentially cause microscopic scratches. The metal particle layer may include, but is not limited to, copper, steel, brass, bronze, or cobalt, and the metal particle layer may have a thickness of at least one particle. The continuous metal matrix may include, but is not limited to, nickel or copper. As with the first embodiment, in the second embodiment, preferred (but not required) particle size ranges may be from about 0.1 microns to about 50 microns, or from about 0.25 microns to about 1.0 microns. Preferred (but not required) coating thicknesses may range from about 50 microns to 500 microns, or from about 100 microns to about 200 microns.

As represented in FIG. 4, in a third embodiment, a layer of metal-coated diamond or cBN particles 40 in a metal matrix 41 can be plated onto the inner surface of a quench die 42 using electroless or electrolytic methods. . A metal coating 43 on the surface of the diamond or cBN particles 40 can allow the coating layer of the present disclosure to achieve the desired function, and the metal coating 43 can include, but is not limited to, titanium, chromium, nickel, cobalt, copper, tantalum, Iron, silver, or combinations thereof, or multiple layers of any of the above materials. The cladding layer may have a thickness greater than one superabrasive grain, and the metal matrix may include, but is not limited to, nickel or copper. For example, preferred (but not required) particle sizes and layer thicknesses of coatings may be similar to those described for the first and second embodiments above. The metal coating on the surface of the superabrasive grains may or may not coat the entire surface of each grain. Preferably, the metal coating has a maximum thickness that is less than the maximum diameter of the superabrasive grains.

As represented in FIG. 5 , in a fourth embodiment, the quench die cavity 51 may be clad with a layer of metal-coated graphite particles 50 . The layer may be applied to the quenching mold 51 by a thermal spray process. Those skilled in the art will appreciate that other processes can be used to apply this layer. Additionally, the metal coating 52 on the particles may include, but is not limited to, nickel or copper. The layer of metal-coated graphite particles employed in this technique may be relatively porous and open-structure, and may be capable of retaining considerable amounts of water. In some embodiments, graphite particles 50 may range in size from about 10 microns to about 500 microns. In another embodiment, particles 50 are available in a size range from 50 to 150 microns. Other granularities are possible. The particle layer may have a thickness between about 0.001 inches and about 0.050 inches. Alternatively, the particle layer may have a total thickness of about 0.1 microns to about 500 microns, about 50 microns to about 500 microns, about 100 microns to about 200 microns, or other suitable dimensions. The weight percentage of metal to graphite may be about 85% metal to about 15% graphite. In an alternative embodiment, the weight percentages of metal and graphite may be about 60% and about 40%, respectively. Alternative ranges may include about 75% metal to about 25% graphite, or about 80% metal to about 20% graphite. Other solid lubricants such as hexagonal boron nitride (hBN), talc, _MoS2, or other materials can be used instead of graphite. In addition to the porous nature of the metal-graphite coating, coated graphite particles can also provide a non-wetting surface resistant to molten glass. This property prevents the molten glass from adhering to the cladding prior to quenching.

As represented in Figure 6, in a fifth embodiment, the layer of metal-graphite particles 60 as described above may include an additional coating 61 of superabrasive material such as diamond or cubic boron nitride. The additional coating 61 may be applied to the quench die 63 to strengthen the metal-graphite coating 62 and improve wear resistance. The composite coating 61 added to the metal-graphite coating 62 can be thin, such as from about 1 micron to about 25 microns, or from about 2 microns to about 10 microns, so that the overall porosity and Water retention capacity will not be significantly reduced. Since the metal-graphite coating 62 may have a loose structure, optionally this additional coating 61 may evenly cover all exposed metal-graphite coating 62 . The composite overcoat 61 may also improve the adhesion between the metal-graphite coating 62 and the associated graphite particles 60 .

In composite coating methods using electroless chemistry to co-deposit hard particles such as superabrasives or silicon carbide, boron carbide, aluminum oxide or other particles, for electroless chemistry in which the particles are suspended The particles may be inert by method. For example, diamond particles suspended in an electroless plating bath may not be autocatalytic to nickel dissolved in the solution, and the nickel may not deposit on the surface of the diamond. When co-deposition of nickel and diamond particles occurs in this case, the resulting composite layer may be homogeneous and may conform to the substrate to which the coating is applied. For example, if a steel plate having a surface roughness Ra of about 0.1 micron is coated with a composite coating comprising diamond particles having a particle size of about 8 microns, the coating produced as such may have a surface roughness of about 0.8 Micron.

However, when a metal layer is deposited onto the surface of the superabrasive or graphite particles, the layer may become autocatalytic to the nickel or other plating metal in the plating bath. Thin layers of titanium and/or chromium may be deposited onto the diamond or cBN particles using chemical vapor deposition (CVD) and/or physical vapor deposition (PVD) techniques. Optionally, the coating on each particle may comprise less than 50% of the total diameter of each particle. In various embodiments, the coating thickness may be less than about 20%, 10%, 5%, or even 1% of the total particle size. Those skilled in the art will appreciate that other techniques may be used. In such cases, when adding fine particles comprising a metal coating such as titanium or chromium to the plating bath, the surface area of the metal coating may be significantly greater than that normally recommended for stable operation of the bath. When the bath is properly driven such that autocatalytic deposition of metal from the bath occurs, the metal in solution begins to plate at a high rate, primarily due to the large surface area of metal that can coat the particles. Metal-coated particles can become trapped on the substrate surface being coated, but due to the rapid consumption of metal from the bath, the coating can form rapidly and can have many morphologies that build cork and resin surfaces of nodules. The resulting surface features of the coating can have a surface roughness of about 40 microns, a peak-to-valley height of about 250 microns, and an average peak-to-valley distance of about 200 microns, and can have the ability to retain surface moisture. A deviation of +/-50% is possible for each of these values. Although other dimensions are possible, the overall thickness of the composite coating in this case can be on the order of about 200 to about 500 microns, which is thicker than a composite coating made with particles without a metal coating . It is also worth noting that nodular features formed by rapid decomposition of the plating bath can be on the order of about 50 microns to about 300 microns in diameter. Other sizes are possible.

Because the metal cladding adheres to the mold base, the composite cladding is highly wear resistant. The cladding can be applied to structural materials such as steel, reinforced composites, ceramics or plastics, and thus can reduce catastrophic failures in use. Part life may be extended due to the improved wear, corrosion and erosion resistance imparted by the coating.

The coatings described herein can provide suitable porosity and water retention properties. For example, in some embodiments, after submerging a coated quench form in water, the coated article can retain a volume of water up to about 0.4 per cubic millimeter of coating. cubic millimeter to about 0.9 cubic millimeter.

Example

The main function of the bulb quenching mold is to retain moisture on the surface and in the pores of the cladding. The efficiency of the quench die is directly proportional to the amount of water that can be held in the coating. A technique was developed to measure the moisture retention of the coating on thin steel sheets that have been coated with composite diamond coating (CDC). A series of laboratory tests were performed in which several small (2 inch by 3 inch) steel plate.

CDC-8, -15 and -Ti claddings were applied to the steel plates using techniques based on US Patent No. RE33767 and using techniques described in US Patent No. 6,306,466, the aforementioned US Patent The disclosure of is incorporated herein by reference. The CDC-8 coating is made of 8 micron diamond particles in an electroless nickel-phosphorus matrix and is approximately 0.002 inches thick. The CDC-15 coating is made of 15 micron diamond particles in an electroless nickel-phosphorous matrix and is approximately 0.002 inches thick. The CDC-Ti cladding is made of 8 micron diamond particles in an electroless nickel-phosphorous matrix with a titanium cladding on the outer layer of the diamond, and the composite cladding is greater than 0.004 inches thick.

Example 1 . The cork/resin panels were weighed on a balance and tare-corrected to zero, then submerged in a beaker of water at a common level. Excess water was shaken off and the panels were weighed immediately and the weight of moisture retained was recorded. The panels were then allowed to stand in a vertical position for one minute before being weighed again. A series of erecting and weighing operations were repeated for seven minutes. As can be seen from the results in Figure 7, the cork coating, which was the standard coating used in the quench die today, retained 0.48 grams of water.

Example 2 . Plates were clad with composite diamond cladding made of 8 micron diamond (CDC-8) and 15 micron (CDC-15) diamond, and weighed on a balance and tared to zero, then placed in a beaker of water with a common The level height is immersed in water. Excess water was shaken off and the panels were weighed immediately and the weight of moisture retained was recorded. The panels were then allowed to stand in a vertical position for one minute before being weighed again. A series of erecting and weighing operations were repeated for seven minutes. As can be seen from the results in Figure 7, the composite diamond coating comprising CDC-8 and CDC-15 diamond on the plate retained approximately 0.10 grams of water.

Example 3 . Composite diamond-coated plates made of 8 micron diamond coated with a thin layer of titanium (titanium content was determined to be 30% by weight) were weighed on a balance and tared to zero, then placed in a beaker of water at The common level is submerged in water. Excess water was shaken off and the panels were weighed immediately and the weight of moisture retained was recorded. The panels were then allowed to stand in a vertical position for one minute before being weighed again. A series of erecting and weighing operations were repeated for seven minutes. Figure 8 illustrates a micrograph of a titanium-coated diamond coating of the present disclosure. As can be seen from the results in Figure 7, the composite diamond coating with titanium-coated diamond particles (CDC-Ti) retained about 0.26 grams of water.

Example 4 . In a ribbon glass former for full-scale production of conventional incandescent light bulbs, the main component of interest and tested is the light bulb quenching mold. In testing, two new molds were obtained from a stock of large similar molds for a large number of standard light bulbs. The test involved applying a composite diamond coating to a mold. The cladding utilizes 8 micron diamond at approximately 40% diamond bulk density and a thickness of 0.001 inches (25 microns). For another mold, the inner surface of the mold was first laser engraved to impart a texture similar to that of the existing sacrificial cladding. After the mold was engraved, a similar composite diamond coating as used in the first mold was applied. The resulting surface for mold 1 is shown in FIG. 9 and that for mold 2 is shown in FIG. 10 .

Example 5 . The steel plate is clad with a nickel-graphite cladding. Prior to cladding, the surface of the panel was cleaned with alcohol to remove any surface grease, and then the panel face was grit blasted with #30 aluminum oxide powder to create a surface roughness. A base layer of Metco 450 thermal spray coating was applied in approximately 0.002 inches to bond the nickel-graphite layer. The nickel-graphite powder used was 307NS commercially available from Sulzer Metco. The powder was applied using a Type 5P spray gun using oxyacetylene gas at the system parameters recommended by Sulzer Metco. The nickel-graphite layers were applied at 0.004 inches and 0.015 inches. Figure 11 is a micrograph of a nickel-graphite coating on a steel plate. Water retention tests were carried out on the nickel-graphite plates and the total amount of water retained in the coating was measured. As shown in Figure 7, the amount of water retained by the steel plate clad on one side (thermal sprayed) was approximately 0.72 grams.

Example 6 . The steel panels from Example 5 were further treated by applying a composite coating as described in Example 2. The composite coating in this example uses 2 micron diamond particles in an electroless nickel matrix. The coating has a thickness of about 10 microns. As can be seen from Figure 12, the diamond, graphite particles and nickel matrix are clearly visible. Water retention and abrasion tests were also performed on this panel and other test panels from previous examples. The results of the water retention test are shown in Figure 7 (TS+CDC), where it can be seen that the panel retained approximately 0.38 grams of water.

While this disclosure has provided numerous details with reference to certain preferred embodiments of the invention, other variations are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description and preferred versions contained in this specification.

Claims (11)

1. quench molds comprises:

Inner chamber; And

Lip-deep coating at described inner chamber; wherein said coating comprises the bed of graphite particles of metallic cover; the bed of graphite particles of wherein said metallic cover also comprises that superabrasive material coating and described superabrasive material are diamond particles or cubic boron nitride particle, and the bed of graphite particles that wherein has a described metallic cover of described superabrasive material coating has porous loose structure.

2. quench molds as claimed in claim 1, wherein the lip-deep described coating at described inner chamber also comprises metallic matrix.

3. quench molds as claimed in claim 1, wherein said metal comprise metal cover or its a plurality of layers of titanium, chromium, nickel, cobalt, copper, tantalum, iron, silver or its combination.

4. quench molds as claimed in claim 1, wherein keep the water of certain volume at the lip-deep coating of described inner chamber, the glassware for drinking water of described certain volume has the volume of 0.4 cubic millimeter to 0.9 cubic millimeter of every cubic millimeter of coating.

5. quench molds as claimed in claim 3, wherein said metal cover comprises copper or nickel.

6. quench molds as claimed in claim 2, wherein, described metallic matrix comprises nickel, chromium, copper, cobalt or its alloy.

7. quench molds as claimed in claim 1, wherein, have the total thickness of 50 microns to 500 microns at the lip-deep coating of described inner chamber.

8. quench molds as claimed in claim 1, wherein said particle form 10% weight of described coating to 80% weight.

9. quench molds as claimed in claim 1, wherein additional described superabrasive material coating has the thickness of 1 micron to 25 microns.

10. quench molds as claimed in claim 3, wherein said metal cover form 60% weight of bed of graphite particles of described metallic cover to 80% weight.

11. quench molds as claimed in claim 3, wherein said metal cover has the thickness of 200 microns to 500 microns.

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