Sand Casting Mould Anti-Adhesive Coating for Epoxy Resin Reuse
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Solution Overview
Problem
Existing methods for preparing sand casting moulds, especially for complex and large products, are costly and time-consuming, and the surface structure from 3D printing with sand is too porous, leading to permanent bonding with epoxy resin, making repeated use impossible and requiring complex vacuum techniques for infiltration.
Innovation Solution
A method involving chemical infiltration of sand casting moulds using chemosetting or thermosetting materials with anti-adhesive properties, followed by applying a protective coating via spraying, immersion, or deposition methods to close pores and prevent resin penetration, eliminating the need for vacuum techniques and enabling multiple uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sand printing is used to create mould surfaces, then manufacturing cost and time are reduced, but the surface becomes too porous causing permanent bonding with epoxy resin and making repeated use impossible
Solution Approach 1:
A protective coating is applied to the sand printing mould surface before the epoxy resin casting process. This preliminary protective layer prevents the porous sand surface from bonding permanently with the epoxy resin, allowing the mould to be reused multiple times without degradation.
2Manufacturing precision
If vacuum suction is used for resin infiltration through sand layers, then complete infiltration is achieved, but the process becomes complex and time-consuming
Solution Approach 1:
The protective coating is applied only to the external surface of the sand printing mould, extracting the infiltration function from the porous sand structure itself. This allows resin to be applied without vacuum suction, as the coating prevents penetration while maintaining surface integrity, thereby eliminating complex vacuum equipment.
3Reliability
If a protective coating is applied to prevent resin bonding, then mould reusability is improved, but an additional processing step is required
Solution Approach 1:
The protective coating material is selected with specific parameters: it must have appropriate viscosity for easy application, correct chemical composition to prevent bonding with epoxy resin, and suitable curing characteristics. By optimizing these parameters, the coating provides effective protection while minimizing application time and complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the process, reduces costs by allowing multiple uses of the moulds, provides mechanical reinforcement and anti-adhesive properties, and avoids the complexity of vacuum infiltration, resulting in a durable and cost-effective solution for casting resin or cellulose products.
Implementation Method 1
infiltration of the mould structure is done chemically, avoiding vacuum suction of infiltrating resin through the layers of foundry sand with activator mixture
Implementation Method 2
saturating of the raw mould structure with chemosetting or thermosetting material
Implementation Method 3
The operation of applying of an external protective coating is carried out by means of any spraying, immersion or deposition method
Implementation Method 4
The operation of applying of the protective layer on external surfaces of a sand casting mould by means of the deposition method is conducted by means of Physical Vapour Deposition (PVD) or Chemical Vapour Deposition (CVD) from the gas phase
Implementation Method 5
material with anti-adhesive properties is used for a protective coating in the form of organic chemosetting, thermosetting, light-curing material or in the form of inorganic material, including metal
Data Source
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AI summary
A method of making sand casting moulds with a protective coating for a multiple process of reactive moulding of insulation components and products made by filling up a mould cavity with polymer materials, including composites, based particularly on epoxy resins or composites based on cellulose materials, the method characterised in that the process of infiltration of the mould structure is performed chemically by soaking through the raw mould structure (1) with chemosetting or thermosetting material. The application of a protective layer (3) on external surfaces of a sand casting mould is done by means of any spraying, immersion or deposition method, whereas material with anti-adhesive properties is used for the protective coating in the form of organic chemosetting, thermosetting, light-curing material or in the form of inorganic material, including metal.