# US 9,433,998 B2 · Surface-treated mold and method of producing surface-treated mold

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- Number: US 9,433,998 B2
- Document ID: US9433998B2
- Status: Granted
- Kind: B2
- Application number: 14/148,165
- Filed: 2014-01-06
- Published: 2014-05-01
- Granted: 2016-09-06
- Earliest claimed: 2009-11-27
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Toyota Jidosha Kabushiki Kaisha
- Inventors: Yuichi Furukawa; Jun Yaokawa; Yasushi Iwata
- Web page: https://patentgrep.com/patent/US9433998B2

## CPC

- B22C 3/00: Selection of compositions for coating the surfaces of moulds, cores, or patterns
- B05D 5/08: to obtain an anti-friction or anti-adhesive surface (rendering particulate materials free-flowing in general, e.g. making them hydrophobic B01J2/30)
- B22C 9/061: {Materials which make up the mould}
- B22D 17/2209: {Selection of die materials (for permanent moulds B22C9/061)}
- C23C 8/02: Pretreatment of the material to be coated (C23C8/04 takes precedence)
- C23C 8/20: Carburising
- C23C 18/165: {Multilayered product (layered product B32B)}
- C23C 18/1689: {After-treatment}
- C23C 18/1696: {Control of atmosphere}
- C23C 18/1698: {Control of temperature}
- C23C 18/32: Coating with nickel, cobalt or mixtures thereof with phosphorus or boron (C23C18/50 takes precedence)
- C23C 28/00: Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)

## Abstract

A surface-treated mold that includes a mold, a metal layer that is provided on a surface of the mold and contains at least one metal selected from nickel, chromium, tungsten and brass, and a carbon film that is provided on a surface of the metal layer, wherein the metal layer contains carbon, and the carbon concentration in the metal layer is higher between the boundary with the carbon film and the center of the metal layer than that between the boundary with the mold and the center of the metal layer.

## Claims

### Claim 1

A method of producing a surface-treated mold, comprising:
forming an amorphous metal layer that contains at least one metal selected from the group consisting of nickel, chromium, tungsten and brass on a surface of a mold; and
forming a carbon film over the amorphous metal layer while heating the amorphous metal layer at a temperature of 410° C. to 510° C.,
wherein the mold is made of tool steel or iron.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the amorphous metal layer is formed by electroless nickel plating.

### Claim 3 (depends on 1)

The method according to claim 1, wherein a gaseous mixture of a hydrocarbon gas and a diluent gas is supplied for at least a part of the time period during which the carbon film is formed on the surface of the amorphous metal layer.

### Claim 4 (depends on 1)

The method according to claim 1, wherein a gaseous mixture of acetylene and ammonia is supplied for at least a part of the time period during which the carbon film is formed on the surface of the amorphous metal layer.

### Claim 5 (depends on 4)

The method according to claim 4, wherein the carbon film on the surface of the amorphous metal layer is formed by supplying a gaseous mixture of acetylene and ammonia and subsequently supplying only ammonia.

### Claim 6 (depends on 1)

The method according to claim 1, wherein a carbon solid-solution diffusion layer is formed between the amorphous metal layer and the carbon film.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the carbon film is fibrous.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the carbon film is formed of at least one of carbon nanocoils, carbon nanotubes and carbon nanofilaments.