Blow mold for molding a container

Abstract

A blow mold is disclosed. The mold includes a pair of mold halves having an operative configuration wherein the mold halves together define a cavity for a container, the container having a main body and a characteristic selected from the group of characteristics consisting of: a push-up base; an integral finish; and an embossed or a debossed feature. Each of the pair of mold halves has a first portion and a second portion formed integrally with the first portion. When the pair of mold halves is in the operative configuration, the first portions collectively define the main body and the second portions collectively define the characteristic. At least one of the pair of mold halves has a relatively soft substrate portion and a relatively hard surface layer formed integrally with the substrate portion.

1 . A blow mold comprising:
 a pair of mold halves having an operative configuration wherein said mold halves together define a cavity for a container, the container having a main body and a characteristic selected from the group of characteristics consisting of:   a push-up base;   an integral finish; and   an embossed or a debossed feature,   wherein   each of the pair of mold halves has a first portion and a second portion formed integrally with the first portion;   when the pair of mold halves is in the operative configuration, the first portions collectively define the main body and the second portions collectively define the characteristic; and   at least one of the pair of mold halves has a relatively soft substrate portion and a relatively hard surface layer formed integrally with the substrate portion.   
     
     
         2 . A mold according to  claim 1 , wherein the substrate portion is an aluminum alloy and the surface layer is a metal-matrix composite (MMC). 
     
     
         3 . A mold according to  claim 2 , wherein the MMC comprises an aluminum-nickel alloy matrix having WC particles embedded therein. 
     
     
         4 . A mold according to  claim 3 , wherein the WC particles are distributed in the aluminum-nickel alloy matrix in an amount in a range of from 5 wt % to 50 wt %, based on the weight of the composite. 
     
     
         5 . A mold according to  claim 3 , wherein the WC particles are distributed in the aluminum-nickel alloy matrix in an amount in a range of from 10 wt % to 40 wt %, based on the weight of the composite. 
     
     
         6 . A mold according to  claim 3 , wherein the WC particles are distributed in the aluminum-nickel alloy matrix in an amount in a range of from 20 wt % to 35 wt %, based on the weight of the composite. 
     
     
         7 . A mold according to  claim 3 , wherein the WC particles are distributed in the aluminum-nickel alloy matrix in an amount of about 27 wt %, based on the weight of the composite. 
     
     
         8 . A mold according to  claim 4 , wherein the aluminum-nickel alloy matrix comprises Al-12Si alloy alloyed with nickel. 
     
     
         9 . A mold according to  claim 8 , wherein the MMC comprises 1.5-5.4 wt % Ni, based on weight of the composite. 
     
     
         10 . A mold according to  claim 8 , wherein the MMC comprises 2.4-3.6 wt % Ni, based on weight of the composite. 
     
     
         11 . A mold according to  claim 8 , wherein the MMC comprises 3 wt % Ni, based on weight of the composite. 
     
     
         12 . A mold according to  claim 9 , wherein the aluminum alloy is selected from Al 2024 all, Al 2124 all, Al 2219 T31 though T87, Al 6009 all, Al 6010 all, Al 6061 all, Al 6061 T4 through T6511, Al 7075 T6 through T7351, Al 7050 all or Al 7475 all. 
     
     
         13 . A mold according to  claim 9 , wherein the aluminum alloy comprises Al 7075-T6 through T7351. 
     
     
         14 . A mold according to  claim 9 , wherein the aluminum alloy is Al 7075-T651. 
     
     
         15 . A process of producing a mold half comprising:
 applying a layer of a metal-matrix composite (MMC) to a piece of machined aluminum alloy to form a composite structure; and   machining the composite structure.   
     
     
         16 . A process according to  15 , wherein the MMC is an aluminum-nickel alloy matrix having WC particles embedded therein. 
     
     
         17 . A process according to  claim 16 , wherein the MMC layer is formed by laser cladding. 
     
     
         18 . A process according to  claim 17 , wherein
 the WC particles are distributed in the aluminum-nickel alloy matrix in an amount in a range of from 20 wt % to 35 wt %, based on the weight of the composite;   the aluminum-nickel alloy matrix comprises Al-12Si alloy;   the MMC comprises 1.5-5.4 wt % Ni, based on weight of the composite; and   the aluminum alloy is Al 7075-T6 through T7351.   
     
     
         19 . A process according to  claim 18 , wherein the composite structure is machined into the mold half. 
     
     
         20 . A process according to  claim 18 , wherein one or more inserts are secured to the machined composite structure to form the mold half.