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Molded article

a technology of molded articles and molded parts, applied in the field of molded articles, can solve the problems of waste of materials, difficulty in assembling, and difficulty in assembling, and achieve the effect of precise detail

Inactive Publication Date: 2009-12-17
OSAKI MASAYUKI
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a molded article with precise detail in a complicated shape and a method of producing it. The molded article contains inorganic powder, inorganic fiber, organic fiber, thermosetting resin, and heat expandable particles. The heat expandable particles are added in a specific amount to the mixture to help with the shaping process. The method involves preparing a slurry, forming a wet preform, and drying it in a mold while expanding the heat expandable particles. Overall, the invention allows for the creation of detailed and complex molded articles with precision.

Problems solved by technology

Making a wooden or metal pattern requires skill and expensive equipment.
Such a pattern is expensive and heavy and, moreover, gives rise to a disposal problem and is therefore unsuited to the production of castings except mass-produced items.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0070]A molded article was produced from a stock slurry having the formulation described below. A casting was produced using the resulting molded articles as a casting mold (main mold). The resulting casting was evaluated with respect to shape transfer, flash, and metal penetration as follows. The results are shown in Table 1. As previously stated, “flash” is a casting defect that occurs, in producing a casting by pouring molten metal into a casting mold assembled by joining two molded articles, when the molten metal enters a gap between the parting faces of the molded articles and solidifies as such. “Metal penetration” is a casting defect that occurs when molten metal enters a crack or a void on the cavity surface of a casting mold and solidifies as such.

Preparation of Stock Slurry

[0071]The inorganic powder, inorganic fiber, organic fiber, and heat expandable particles shown below were dispersed in water to prepare a slurry having a concentration of about 1% (a total concentration...

example 2

[0081]Molded articles were produced in the same manner as in Example 1, except for altering the formulation of the stock slurry and the drying / shaping conditions of the preform as described below. A casting was produced using the resulting molded articles as a main mold. The resulting casting was evaluated in the same manner as in Example 1. The results obtained are shown in Table 1.

Formulation of Stock Slurry

[0082]Inorganic powder: tabular graphite (scaly graphite)

Inorganic fiber: PAN carbon fiber (Pyrofil (trade name) available from Mitsubishi

Rayon Co., Ltd.; length: 3 mm; percent shrinkage: 0.1%)

Organic fiber: paper fiber (recycled newspaper; average length: 1 mm; freeness (CSF): 150 cc)

Heat expandable particles: heat expandable microcapsules (Matsumoto Microsphere F-105D (trade name) from Matsumoto Yushi-Seiyaku Co., Ltd.)

Thermosetting resin: phenol resin (S890 from Air Water Bellpearl, Inc.)

Compounding Ratio (%): inorganic powder / inorganic fiber / organic fiber / thermosetting resi...

example 3

[0087]Molded articles were produced in the same manner as in Example 1, except for changing the formulation of the stock slurry as follows. A casting was produced using the resulting molded articles as a main mold. The resulting casting was evaluated in the same manner as in Example 1. The results obtained are shown in Table 1.

Formulation of Stock Slurry

[0088]Inorganic powder 1: tabular graphite (scaly graphite)

Inorganic powder 2: obsidian

Inorganic powder compounding ratio: tabular graphite (scaly graphite) / obsidian=50 / 50

Inorganic fiber: PAN carbon fiber (Pyrofil (trade name) available from Mitsubishi

Rayon Co., Ltd.; length: 3 mm; percent shrinkage: 0.1%)

Organic fiber: paper fiber (recycled newspaper; average length: 1 mm; freeness (CSF): 150 cc)

Heat expandable particles: heat expandable microcapsules (Matsumoto Microsphere F-105D (trade name) from Matsumoto Yushi-Seiyaku Co., Ltd.)

Thermosetting resin: phenol resin (S890 from Air Water Bellpearl, Inc.)

Compounding Ratio (%): inorgani...

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Abstract

A molded article contains inorganic powder as a main component and further contains inorganic fiber, organic fiber, a thermosetting resin, and heat expandable particles, the heat expandable particles being present in an amount of 0.5% to 10% by mass based on the total mass of the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the heat expandable particles. The inorganic powder is preferably graphite. The inorganic fiber is preferably carbon fiber. The organic fiber is preferably pulp fiber. The thermosetting resin is preferably a phenol resin.

Description

[0001]This application is a Continuation of co-pending application Ser. No. 11 / 579,955, and for which priority is claimed under 35 U.S.C. § 120. Application Ser. No. 11 / 579,955 is a National Stage Entry of PCT International Application No. PCT / JP2006 / 309822, filed on May 17, 2006, and for which priority is claimed under 35 U.S.C. § 120. This application also claims priority under 35 U.S.C. § 119(a) on Patent Application No. 2005-148746 filed in Japan on May 20, 2005 and Patent Application No. 2006-135719 filed in Japan on May 15, 2006. The entire contents of each of the above documents are hereby incorporated by reference.TECHNICAL FIELD[0002]The present invention relates to a molded article made mainly of inorganic powder and a method of producing the same. In particular, it relates to a molded article suited for use as a mold for producing a casting or a structure (hereinafter inclusively referred to as a casting mold, etc.) and a method of producing the same.BACKGROUND ART[0003]I...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D21J3/00
CPCB22C9/00D21J3/00B29C41/003B29C41/16B29C43/003B29C43/36B29C44/12B29C44/445B29C2043/046B29K2101/10B29K2105/0061B29K2105/048B29K2105/06B29K2105/12B29K2105/165B29K2303/04B29K2311/10B29K2503/04B29K2503/08B29C33/3807B29C43/04B22C1/00B29C67/24
Inventor OSAKI, MASAYUKI
Owner OSAKI MASAYUKI