Glass molding die, renewal method thereof, and glass fabricated by the molding die

1. A renewal method for a glass molding die, comprising: providing a used glass molding die comprising a substrate, a nickel-phosphorous alloy layer, with phosphorous content 30 wt % or less, overlying the substrate, a first intermediate layer overlying the nickel-phosphorous alloy layer, and a first passivation film overlying the first intermediate layer; removing the first passivation film and first intermediate layer using the nickel-phosphorous alloy layer as a stop layer, exposing the nickel-phosphorous alloy layer; cleaning the exposed nickel-phosphorous alloy layer; forming a second intermediate layer overlying the nickel-phosphorous alloy layer; and forming a second first passivation film overlying the second intermediate layer.

2. The method as claimed in claim 1 , wherein the substrate comprises tungsten carbide.

3. The method as claimed in claim 1 , wherein the nickel-phosphorous alloy layer further comprises approximately 0.1 to 10 wt % of high melting point metals or alloys thereof.

4. The method as claimed in claim 1 , wherein the first passivation film and first intermediate layer are removed by abrasive machining or grinding.

5. The method as claimed in claim 1 , further comprising polishing the exposed nickel-phosphorous alloy layer using grinding when the first passivation film and first intermediate layer are removed.

6. The method as claimed in claim 5 , wherein the phosphorous content of the nickel-phosphorous alloy layer is between about 1 to 10 wt %.

7. The method as claimed in claim 1 , further comprising polishing the exposed nickel-phosphorous alloy layer using diamond turning when the first passivation film and first intermediate layer are removed.

8. The method as claimed in claim 7 , wherein the phosphorous content of the nickel-phosphorous alloy layer is between about 4 to 30 wt %.

9. The method as claimed in claim 8 , wherein the phosphorous content of the nickel-phosphorous alloy layer is between about 10 to 30 wt %.

10. The method as claimed in claim 7 , wherein the first nickel-phosphorous alloy layer and second nickel-phosphorous alloy layer further comprise about 0.1 to 10 wt % of tungsten, tantalum, manganese, or combinations thereof, and the first nickel-phosphorous alloy layer and second nickel-phosphorous alloy layer are approximately the same or different composition.

11. The method as claimed in claim 1 , further comprising correcting a surface profile of the exposed nickel-phosphorous alloy layer when the first passivation film and first intermediate layer are removed.

12. The method as claimed in claim 11 , wherein the surface profile of the exposed nickel-phosphorous alloy layer is corrected by diamond turning.

13. The method as claimed in claim 12 , wherein the phosphorous content of the nickel-phosphorous alloy layer is between about 4 to 30 wt %.

14. The method as claimed in claim 1 , wherein the second intermediate layer is about 0.1 to 1 μm thick.

15. The method as claimed in claim 1 , wherein the first passivation film and second passivation film comprise combinations of at least two of iridium, rhenium, platinum, ruthenium, rhodium, and osmium, and the first passivation film and second passivation film are approximately the same material.

16. The method as claimed in claim 1 , wherein the passivation film is about 0.02 to 0.3 μm thick.

17. A renewal method for a glass molding die, comprising:

providing a used glass molding die comprising a substrate, a first nickel-phosphorous alloy layer, with phosphorous content as large as 30 wt % or less, overlying the substrate, a first intermediate layer overlying the nickel-phosphorous alloy layer, and a first passivation film overlying the first intermediate layer;

removing the first passivation film and first intermediate layer using the first nickel-phosphorous alloy layer as a stop layer, exposing the first nickel-phosphorous alloy layer;

removing the first nickel-phosphorous alloy layer using the substrate as a stop layer, exposing the substrate;

cleaning the exposed substrate;

forming a second nickel-phosphorous alloy layer, with phosphorous content 30 wt % or less, overlying the substrate;

forming a second intermediate layer overlying the second nickel-phosphorous alloy layer; and

forming a second first passivation film overlying the second intermediate layer.

18. The method as claimed in claim 17 , wherein the substrate comprises tungsten carbide.

19. The method as claimed in claim 17 , wherein the first passivation film and first intermediate layer are removed by a diamond grinding wheel assembly.

20. The method as claimed in claim 17 , wherein the first nickel-phosphorous alloy layer is removed by nitric acid.

21. The method as claimed in claim 17 , wherein the second nickel-phosphorous alloy layer is about 20 to 100 μm thick.

22. The method as claimed in claim 17 , wherein the first intermediate layer and second intermediate layer comprise nickel and combinations of at least two of iridium, rhenium, platinum, ruthenium, rhodium, and osmium, and the first intermediate layer and second intermediate layer are approximately the same or different material.

23. The method as claimed in claim 17 , wherein the second intermediate layer is about 0.1 to 1 μm thick.

24. The method as claimed in claim 17 , wherein the first passivation film and second passivation film comprise combinations of at least two of iridium, rhenium, platinum, ruthenium, rhodium, and osmium, and the first passivation film and second passivation film are approximately the same material.

25. The method as claimed in claim 17 , wherein the second passivation film is about 0.02 to 0.3 μm thick.