CN112739512A - 铸模形成组合物及其用途 - Google Patents

铸模形成组合物及其用途 Download PDF

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CN112739512A
CN112739512A CN201980053421.1A CN201980053421A CN112739512A CN 112739512 A CN112739512 A CN 112739512A CN 201980053421 A CN201980053421 A CN 201980053421A CN 112739512 A CN112739512 A CN 112739512A
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casting mold
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伊多·赛拉
希姆里特·芬克尔
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Econcrete Tech Ltd
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Abstract

本发明提供了一种用于形成铸模或模具衬垫的组合物，该组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，所述固体颗粒具有20μm至60μm的平均粒度。

Description

铸模形成组合物及其用途
发明背景
铸造是一种制造工艺，在该制造工艺中，通常将液体材料倒入包含期望形状的空腔(hollow cavity)的模具中，并且然后允许固化。固化的部分还被称为铸件(casting)，将铸件从模具中弹出或拆解出(broken out)以完成该工艺。
石膏和其他化学固化材料，诸如混凝土和聚合物以及塑料树脂，可以使用一次性废弃模具、多次使用的“件”模具或由小的刚性件或柔性材料诸如胶乳橡胶制成的模具(其又由外部模具支撑)来铸造。
模制是通过使用被称为模具或基体的刚性框架将液体或柔软的原材料成型的制造工艺。这本身可能已经使用最终物体的图案或模型来完成。
模具是一种挖空的块状物，其填充有液体或柔软的材料，诸如混凝土。液体在模具内部硬化或凝固，采用模具的形状。模具是铸件的对应物。非常常见的双阀模制工艺使用两个模具，每个模具用于物体的每一半。铰接式模具有多个件，这些件聚集在一起以形成完整的模具，并且然后拆卸以释放成品铸件；它们是昂贵的，但是当铸件形状具有复杂的突出部分时，它们是必要的。
铸模工艺的一个缺点是铸件从模具中释放的部分。该工艺阶段通常需要施加(拆解模具)或使用某种类型的脱模剂。铸造产品的拆解通常使此工艺的收益性受到限制。因此，非常需要提供由负担得起的材料制成的铸模，该铸模在释放铸件时可以容易地拆解。
发明概述
本发明提供了一种组合物，包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间。
在一些实施方案中，所述CaO是以组合物的至少30％wt的量。在一些实施方案中，所述MgO是以组合物的至少0.5％wt的量。在一些实施方案中，所述SiO是以组合物的至少0.5％wt的量。在一些实施方案中，所述Al2O3是以组合物的至少0.5％wt的量。在一些实施方案中，所述CaO是以组合物的在约30％wt至60％wt之间的量。在一些实施方案中，所述MgO是以组合物的在约0.5％wt至20％wt之间的量。在一些实施方案中，所述SiO是以组合物的在约0.5％wt至5.5％wt之间的量。在一些实施方案中，所述Al2O3是以组合物的在约0.5％wt至1.5％wt之间的量。
在一些实施方案中，本发明的所述组合物还包含Fe2O3、TiO2、K2O、Na2O、P2O5、Mn2O3和SO3及其任何组合中的至少一种。
本发明还提供了一种组合物，该组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间，该组合物用于制备铸模。
在一些实施方案中，所述铸模是可固化材料铸模。在其他实施方案中，所述铸模是模具衬垫(mold-liner)。在另外的实施方案中，本发明的所述铸模可以通过用水洗涤它而降解或拆解。
当提及“可固化材料”时，应当理解为涵盖与其预固化形式相比，在暴露于固化工艺时变得硬化的任何材料，所述固化工艺包括但不限于热、压力、蒸汽、添加剂、能量(UV、IR、微波、X射线等)、辐射、硫化等等或其任何组合。在固化工艺期间，材料由于改变物理性质和/或化学性质的内部过程而硬化，这样的过程包括但不限于：形成交联键、失水(脱水)、减小材料的聚合物链之间的空间等等。
可固化材料的实例包括混凝土、树脂、聚合物、热固性聚合物、热塑性聚合物、石膏等及其任何组合。在一些实施方案中，所述可固化材料是混凝土。
当提及由本发明的组合物制成的铸模的拆解时，应当理解为涉及铸模的崩解，以便将其拆解成部分并将其从其中的铸造的固化材料中取出。使用水进行拆解。
本发明还提供了一种铸模，该铸模包括组合物，所述组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间。
本发明还提供了一种模具衬垫，该模具衬垫包括组合物，所述组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间。
本发明还提供了一种形成铸模的方法，该方法包括以下步骤：(a)提供组合物，该组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间；(b)将所述组合物与水混合，以便形成柔软的湿混合物；(c)由所述湿混合物形成三维模具；(d)干燥所述模具以便形成干铸模。
本发明还提供了一种形成可固化材料铸造产品的方法，该方法包括以下步骤：(a)提供具有呈所述产品的形式的空腔(empty cavity)的铸模；所述铸模包括包含CaO、SiO、MgO、Al2O3的固体颗粒的组合物，其中所述固体颗粒的平均粒度在约20μm至60μm之间；(b)用预固化材料填充所述铸模；(c)在所述填充的铸模中将所述材料固化；(d)用水洗涤所述铸模，以便拆解所述铸模；从而接收所述铸造产品。
本发明还提供了一种形成图案化的可固化材料产品的方法，该方法包括以下步骤：(a)提供包含CaO、SiO、MgO、Al2O3的固体颗粒的图案形成组合物，其中所述固体颗粒的平均粒度在约20μm至60μm之间；(b)将所述图案形成组合物与水混合，以便形成柔软的湿混合物；(c)将所述图案形成组合物施加在可固化材料铸模上；(d)让所述图案形成组合物干燥，以便形成图案化的铸模；(e)用预固化材料填充所述图案化的铸模；(c)在所述填充的图案化的铸模中将所述材料固化；(d)用水洗涤所述图案组合物以便将其拆解；从而接收所述图案化的产品。
附图简述
被视为本发明的主题被特别地指出并且在说明书的结论部分中被明确地要求保护。然而，当与附图一起阅读时，通过参考以下详细描述，本发明(关于组织和操作方法两者)与其目的、特征和优点一起可以被最好地理解，在附图中：
图1示出了如何将本发明的组合物喷射到模制铸件的表面。
图2A-图2B示出了用本发明的组合物喷射之后的铸模。
图3A-图3B示出了在模具剥离之后的固化单元。(参见有(顶部)和没有(底部)施加的组合物的混凝土单元)。
图4A-图4B示出了用水从固化的混凝土表面洗涤组合物之后的固化单元。顶部：有(左)和没有(右下)施加的本发明的组合物的混凝土单元。
将理解，为了简单且清楚阐明，在附图中示出的要素不一定按比例绘制。例如，为了清楚，要素中的某些的尺寸可以相对于其他要素被放大。此外，在认为合适的情况下，参考数字可以在附图中被重复以指示对应的或类似的要素。
本发明的详细描述
在以下详细描述中，大量具体的细节被阐述以便提供对本发明的完全的理解。然而，本领域技术人员将理解，本发明可以在没有这些具体细节的情况下实践。在其他情况下，没有详细地描述公知的方法、程序和部件，以便不使本发明模糊。
实施例1：
1.将本发明的干燥组合物与自来水混合至所需的稠度。为了喷射组合物，加入更多的水，而为了模制组合物(如粘土)，需要更少的水。
2.将组合物喷射在模具的表面上(图1)或附着到模具(以粘土稠度)。
3.组合物在模具的表面上干燥，或以粘土稠度干燥(在附着到模具之前)持续数分钟至数小时，这取决于空气温度(20min至1小时，在30℃，取决于组合物的厚度)(图2)。
4.将混凝土在模具中铸造在所施加的组合物的顶部。
5.在固化之后，剥离模具，并且由本发明的组合物形成的图案可以在与模具接触的混凝土的表面上看到(图3)。
6.自来水被用于溶解来自混凝土面的组合物，在固化的混凝土表面上留下图案、空隙和空间(图4)。
7.具有溶解的组合物的水可以被捕获，并且通过蒸发或分离，组合物可以被再次使用。
尽管本发明的某些特征已经在本文中被图示且描述，但是许多修改、替换、变化和等同物现在将由本领域普通技术人员想到。因此，将理解的是，所附权利要求意图覆盖落在本发明的真实精神范围内的所有这样的修改和变化。

Claims (18)

1.一种组合物，包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间。
2.一种组合物，包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间，所述组合物用于制备铸模。
3.根据权利要求1或2所述的组合物，其中所述CaO是以所述组合物的至少30％wt的量。
4.根据权利要求1或2所述的组合物，其中所述MgO是以所述组合物的至少0.5％wt的量。
5.根据权利要求1或2所述的组合物，其中所述SiO是以所述组合物的至少0.5％wt的量。
6.根据权利要求1或2所述的组合物，其中所述Al2O3是以所述组合物的至少0.5％wt的量。
7.根据前述权利要求中任一项所述的组合物，其中CaO是以所述组合物的在约30％wt至60％wt之间的量。
8.根据前述权利要求中任一项所述的组合物，其中所述MgO是以所述组合物的在约0.5％wt至20％wt之间的量。
9.根据前述权利要求中任一项所述的组合物，其中所述SiO是以所述组合物的在约0.5％wt至5.5％wt之间的量。
10.根据前述权利要求中任一项所述的组合物，其中所述Al2O3是以所述组合物的在约0.5％wt至1.5％wt之间的量。
11.根据前述权利要求中任一项所述的组合物，还包含Fe2O3、TiO2、K2O、Na2O、P2O5、Mn2O3和SO3及其任何组合中的至少一种。
12.根据权利要求2所述的组合物，其中所述铸模是可固化材料铸模。
13.根据权利要求2所述的组合物，其中所述铸模是模具衬垫。
14.一种铸模，包括组合物，所述组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间。
15.一种模具衬垫，包括组合物，所述组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间。
16.一种形成铸模的方法，包括以下步骤：(a)提供组合物，所述组合物包含CaO、SiO、MgO、Al2O3的固体颗粒，其中所述固体颗粒的平均粒度在约20μm至60μm之间；(b)将所述组合物与水混合，以便形成柔软的湿混合物；(c)由所述湿混合物形成三维模具；(d)干燥所述模具以便形成干铸模。
17.一种形成可固化材料铸造产品的方法，包括以下步骤：(a)提供具有呈所述产品的形式的空腔的铸模；所述铸模包括包含CaO、SiO、MgO、Al2O3的固体颗粒的组合物，其中所述固体颗粒的平均粒度在约20μm至60μm之间；(b)用预固化材料填充所述铸模；(c)在所述填充的铸模中将所述预固化材料固化；(d)用水洗涤所述铸模，以便拆解所述铸模；从而接收所述可固化材料铸造产品。
18.一种形成图案化的可固化材料产品的方法，包括以下步骤：(a)提供包含CaO、SiO、MgO、Al2O3的固体颗粒的图案形成组合物，其中所述固体颗粒的平均粒度在约20μm至60μm之间；(b)将所述图案形成组合物与水混合，以便形成柔软的湿混合物；(c)将所述图案形成组合物施加在铸模上；(d)让所述图案形成组合物干燥，以便形成图案化的铸模；(e)用预固化材料填充所述图案化的铸模；(c)在所述填充的图案化的铸模中将所述材料固化；(d)用水洗涤所述图案组合物以便将其拆解；从而接收所述图案化的产品。
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