EP1958717B1 - Component for casting production and method for producing same - Google Patents
Component for casting production and method for producing same Download PDFInfo
- Publication number
- EP1958717B1 EP1958717B1 EP06833601.5A EP06833601A EP1958717B1 EP 1958717 B1 EP1958717 B1 EP 1958717B1 EP 06833601 A EP06833601 A EP 06833601A EP 1958717 B1 EP1958717 B1 EP 1958717B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- casting
- fibers
- inorganic
- mass
- mass content
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/08—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for decreasing shrinkage of the mould, e.g. for investment casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
Definitions
- the present invention relates to a part for producing castings (hereinafter “part for casting” or simply “part”) that can be use as a runner, etc. in the production of castings and a process of making the part.
- JP 2004-174605A a technique relating to a part for casting that can be used as a runner, etc. in the production of castings.
- the technique provides a tube formed of base paper containing organic fiber, inorganic fiber, and a binder, in which the tube is light, easy to handle, and easy to dispose of after use for casting as compared with historically used refractory materials.
- Such a part for casting containing organic fiber, inorganic fiber, and a binder has a minimized content of the organic fiber in order to reduce the generation of combustion gas (hereinafter sometimes referred simply to as "gas") accompanying thermal decomposition of the organic fiber during casting. If the organic fiber content is reduced, however, the components will have poor dispersibility, tending to result in poor formation to yield a high proportion of defective castings. In the case of making base paper by papermaking, in particular, reduction in organic fiber content is liable to produce wavy paper.
- the present invention relates to a satisfactory part for casting and a process of producing the part, in which a specific dispersant is used to allow for reducing an organic fiber content.
- the invention also relates to a satisfactory part for casting having a reduced organic fiber content and a process of producing the part.
- the present inventors have found that a satisfactory part for casting can be obtained by using a specific dispersant even when an organic fiber content is reduced and completed the invention.
- the present invention provides a process of producing a part for casting including the step of preparing a raw material slurry containing inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant.
- the present invention also provides a part for casting containing inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant.
- the part for casting according to the invention is first described based on its preferred embodiment.
- the part 10 of the embodiment shown in Fig. 1 contains inorganic powder, inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a water repellant and, in addition, 0.001% to 10% by mass, preferably 0.01% to 10% by mass, of a sulfonate-based and/or a cellulose-based dispersant based on 100% by mass of the total of the inorganic powder, inorganic fibers, organic fibers, thermosetting resin, papermaking binder, and water repellant.
- Use of such amount of a dispersant enables production of a good part while minimizing the content of the organic fibers.
- the sulfonate-based dispersant examples include a sodium ⁇ -naphthalenesulfonate-formalin condensate, sodium ligninsulfonate, a sodium melaminesulfonate-formalin condensate, an aromatic aminosulfonic acid sodium salt polymer, sodium polystyrenesulfonate, a styrenesulfonic acid-sodium maleinsulfonate copolymer, sodium polycyclopentadienesulfonate, and an aliphatic dienesulfonic acid sodium salt polymer.
- Preferred of them is a sodium ⁇ -naphthalenesulfonate-formalin condensate having a degree of polycondensation of 3 to 6 for consideration of the formation of wet base paper (a wet mat of fiber).
- the cellulose-based dispersant preferably has high water solubility and preferably dissolves completely in a 1% by mass aqueous solution.
- a cellulose-based dispersant is exemplified by cellulose propylene oxide adduct derivatives, e.g., hydroxypropyl cellulose and hydroxypropylmethyl cellulose. Hydroxypropyl cellulose is preferred for consideration of the formation of wet base paper (a wet fiber mat).
- the dispersants can be used either individually or as a combination of two or more thereof.
- the ratio of the inorganic powder/inorganic fibers/organic fibers/thermosetting resin (solid content)/papermaking binder (solid content)/water repellant in the part for casting of the invention is 0-70%/1-60%/1-40%/1-40%/1-10%/0-5% by mass, preferably 40-70%/1-10%/1-25%/1-25%/1-10%/0-5% by mass, more preferably 50-70%/1-8%/1-20%/10-25%/3-7%/0-1% by mass, taking the total of these components as 100% by mass.
- the content of the inorganic powder being within the range recited, the part has good shape retention during pouring, and a fiber molded article has good surface conditions and good release from a mold.
- the content of the inorganic fibers being within the range recited, good papermaking properties and good shape retention during pouring are obtained.
- the organic fiber content being in the range recited, good papermaking properties are obtained, and combustion gas generation during pouring can be held down so as to prevent a blowback (a back-flow of molten metal).
- the thermosetting resin content falling in that range the casting mold has good molding properties, and a fiber molded article has good shape retention after pouring and good surface smoothness.
- the papermaking binder content being in that range, the binder makes the powder component in the slurry cling to the fibers while causing the fibers to moderately intermingle with one another to form flocks optimum for sheet formation and thereby securing good yield.
- the base paper formed by papermaking can be converted into a part for casting with a minimum amount of an adhesive because the adhesive applied is prevented from penetrating into the base paper. Furthermore, after the part for casting is buried in molding sand, the water content of the molding sand is prevented from penetrating into the part.
- the inorganic powder examples include obsidian, mullite, and graphite including flaky graphite and earthy graphite.
- One or more than one kind of the inorganic powders can be selected for use.
- carburizing penetration of carbon into a casting to make the casting brittle
- inorganic powder having a silica content should be used to prevent carburizing from a casting carbide. It is preferred to use obsidian, mullite, etc. as an inorganic powder.
- the carbon content of the casting is 4.2% by mass or more, the part does not need to contain inorganic powder.
- the inorganic fiber serves mainly to constitute the skeleton of the part. For example, it does not burn even with the heat of molten metal and continues serving to retain the shape of the part during casting.
- the inorganic fiber include artificial mineral fibers, such as carbon fiber and rock wool, ceramic fibers, and natural mineral fibers. They can be used either alone or in combination of two or more thereof.
- Carbon fiber that maintains high strength even in high temperatures such as pitch-based carbon fiber or polyacrylonitrile (PAN)-based carbon fiber, is preferred for effectively reducing thermal shrinkage accompanying carbonization of the thermosetting resin.
- PAN-based carbon fiber is especially preferred.
- the inorganic fiber preferably has an average length of 0.1 to 10 mm, more preferably 0.5 to 8 mm, in view of the quality of a fiber molded product obtained by papermaking technique. Continuous fibers of 10 mm or longer may be used as cut in a slurry in a refiner, etc. to have an average fiber length controlled to 0.1 to 10 mm.
- organic fibers examples include pulp fibers, fibrillated synthetic fibers, and regenerated fibers (e.g., rayon fiber). These fibers are used either individually or as a mixture of two or more thereof. Preferred of them is pulp fiber from the viewpoint of sheet forming properties, strength after drying, and cost.
- pulp fibers include not only wood pulp but non-wood pulp, such as cotton pulp, linter pulp, bamboo, and straw. These kinds of pulp, whether virgin or recycled, can be used either alone or in combination thereof. From the standpoint of availability, environmental conservation, and reduction of production cost, used paper pulp is preferred.
- the organic fibers prefferably have an average length of 0.1 to 20 mm, more preferably 0.5 to 10 mm, from the viewpoint of surface smoothness and impact strength of the resulting base sheet.
- thermosetting resin is a component necessary to retain the low- and high-temperature strength of the part 10 and to provide a paper tube with good surface properties which contribute to improve the surface smoothness of a casting.
- the thermosetting resins include phenol resins, epoxy resins, and furan resins. Phenol resins are preferred in view of reduced generation of combustible gas, resistance to burning, and a high carbon residue content after thermal decomposition (carbonization) as high as 25% or more to form a carbonized film to provide a casting with an improved casting surface.
- carbon residue content refers to a value obtained by heating a thermosetting resin sample in a nitrogen atmosphere from room temperature up to 1200°C at a rate of temperature rise of 50°C/min, measuring the mass of the residue, and dividing the mass of the residue with the mass before heating. The mass after heating is lighter than that before heating because combustion gas is released from the resin during heating.
- Usable phenol resins include novolak phenol resins requiring a curing agent and resol type phenol resins requiring no curing agent.
- a low-release phenol resin such as high-molecular-weight resol phenol resins synthesized using a basic catalyst or an acidic catalyst.
- a curing agent is needed. Since the curing agent easily dissolves in water, it is preferably applied to the surface of a dewatered fiber mat. Preferred examples of the curing agent include hexamethylenetetramine.
- the thermosetting resins can be used either individually or as a combination of two or more thereof.
- combustion gas examples include carbon monoxide, carbon dioxide, and hydrocarbons such as methane and ethylene.
- papermaking binder examples include natural polymers such as starch, gelatin, guar gum, and carboxymethyl cellulose (CMC); water soluble synthetic polymers such as KAIMEN (polyamideamine-epichlorohydrin resin), polyvinyl alcohol (PVA), polyacrylamide (PAM), and polyethylene oxide (PEO); styrene-butadiene latices, acrylonitrile-butadiene latices, acrylic latices, and vinyl acetate latices; and inorganic binders such as colloidal silica and alumina-based binders. Preferred of them are KAIMEN, CMC, and acrylic latices for their powder-fixing properties.
- KAIMEN polyamideamine-epichlorohydrin resin
- PVA polyvinyl alcohol
- PAM polyacrylamide
- PEO polyethylene oxide
- styrene-butadiene latices acrylonitrile-butadiene latices
- the papermaking binder is preferably used in an amount of 0.01% to 5%, more preferably 0.02% to 1%, on a solid basis based on the mass of the organic fibers.
- These papermaking binders can be used either individually or as a combination of two or more thereof.
- the part 10 can contain a water repellant to prevent penetration of the adhesive described supra into base paper and to prevent loss of strength due to moisture absorption.
- Silicone surface active agents, fluorine-containing surface active agents, fat and oil type surface active agents, hydrophobic surface active agents, and hydrophobic polymers can be used as a water repellant.
- the water repellant is preferably applied to both the inner and outer sides of the part 10 and dried to prevent deterioration of strength due to moisture absorption.
- the water repellant is advisably used in the form of an aqueous solution or emulsion that is convenient to handle upon use.
- the water repellants may be used either individually or as a combination of two or more thereof. Silicone, fluorine-containing or fat and oil type emulsions are preferably used.
- the water repellant When the water repellant is added to a slurry, particularly preferred is an alkyl ketene dimer (AKD), which exhibits excellent water repellency in a neutral region at a small amount and is superior in acid resistance and alkali resistance to rosin, etc.
- the water repellant may be added in an adequate amount to a raw material slurry or applied to the part. Coating techniques include spraying, brush coating, dipping, and pouring. Spraying, dipping or pouring is preferred for productivity. Coating by "pouring” as used here is achieved by hosing a pumped liquid over the part to be coated. In cases where the part for casting is used in a dry working environment or when the thermosetting resin serves for water repellency depending on its kind or amount used, the water repellant may be dispensed with.
- the part 10 may contain other components such as a flocculant and a colorant in appropriate amounts in addition to the above described components.
- the part 10 preferably has a surface roughness Ra of 20 ⁇ m or less, more preferably 10 ⁇ m or less.
- the surface roughness Ra is measured, e.g., with Surtronic 10 from Rank Taylor Hobson.
- the part 10 is preferably formed of base paper containing the aforementioned components.
- the base paper preferably has a tensile strength of 40 N/15 mm or more, more preferably 80 N/15 mm or more.
- the tensile strength is measured in a tensile test of a 15 mm wide specimen cut out of 0.7 mm thick base paper on a Tensilon universal tester RTA500 from A & D Co., Ltd. When the thickness of a sample is not 0.7 mm, the tensile strength as measured is converted to strength per unit cross-sectional area for comparison.
- Base paper having a tensile strength within the above range does not tear or break when spirally wound to make paper tubing as a part for casting as in the present embodiment.
- the part 10 preferably has a compressive strength of 20 N or higher, more preferably 40 N or higher, before use in casting.
- compressive strength is a compressive strength of the wall of tubing measured as follows. A 60 mm wide specimen cut out of a part for casting is set on a compressive strength testing instrument (e.g., a Tensilon universal tester RTA 500 from A & D) with its cut area horizontal and compressed at a rate of 10 mm/min.
- the thickness of the part 10 is subject to variation according to where it is applied, it is preferably 0.5 to 6 mm, more preferably 1 to 3 mm, for securing strength required of a part for casting and air permeability and reducing the production cost.
- the part 10 before use in casting prefferably has a water content of not more than 20% by mass, more preferably 10% by mass or less, to minimize water vapor generation on contact with molten metal.
- Water vapor generation causes blowback (back flow) of molten metal from the pour spout.
- the part 10 is composed of two tubular paper plies 11 and 12 each formed of spirally wound base paper.
- the production of the part 10 starts with preparation of base paper for making the tubular paper plies 11 and 12.
- Respective raw material slurries for the base paper for making the tubular paper plies 11 and 12 are prepared from the above-described inorganic powder, inorganic fibers, organic fibers, thermosetting resin, papermaking binder, and dispersant. Each of the slurries is converted to a sheet form (wet fiber mat), dewatered, and dried in accordance with a wet papermaking technique to obtain base paper.
- Examples of the dispersing medium of the slurry include water, white water, and solvents such as ethanol and methanol. Water is preferred in view of stability in wet fiber mat formation and dewatering, stability of quality of the resulting base paper, cost, and ease of handling.
- the slurry can contain additives including a flocculant and an antiseptic.
- the slurry thus prepared is then converted into base paper for making paper tubing by a papermaking process.
- Papermaking can be carried out by any technique selected from, for example, continuous papermaking methods using a cylinder paper machine, a Fourdrinier paper machine, a short-wire paper machine or a twin-wire paper machine, and batchwise papermaking methods including manual papermaking.
- the wet fiber mat is dewatered to reduce its water content preferably to 30% or smaller, more preferably to 10% or smaller.
- Dewatering of the fiber layer can be conducted by, for example, suction, blowing pressurized air or pressing with a pressure roll or a pressure plate.
- the dewatered fiber mat is forwarded to a drying step. Any means for drying that has conventionally been used to dry paper can be used in the drying step.
- the base paper after dewatering and drying preferably has a tensile strength of 40 N/15 mm or more, more preferably 80 N/15 mm, to be wound into tubing.
- the tensile strength is measured in a tensile test of a 15 mm wide specimen cut out of 0.7 mm thick base paper on the above mentioned Tensilon universal tester. When the thickness of samples to be measured is not 0.7 mm, the tensile strength as measured is converted to strength per unit cross-sectional area for comparison.
- the base paper after dewatering and drying preferably has a buckling strength of 3 N or higher, more preferably 4 N or higher, in view of the strength of the resulting part for casting.
- the buckling strength is measured by a 3-point bending test as follows. A specimen of base sheet measuring 60 mm in width and 100 mm in length is set on a tester with a 40 mm span length, and compressed from above by an indenter having a width of 60 mm and a diameter of 6 mm at the tip. From the same viewpoint, the base paper after dewatering and drying preferably has a buckling displacement of 3 mm or more, more preferably 5 mm or more.
- the term "buckling displacement" means the amount of displacement of base paper at the maximum stress point in the above described 3-point bending test.
- the base paper after dewatering and drying generates not more than 250 cc/g, more preferably not more than 200 cc/g, of combustion gas per unit mass of the part at 1000°C.
- the amount of combustion gas generated is measured using equipment for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.).
- the amount of combustion gas generated is preferably as small as possible.
- the practically reachable lower limit is 0.1 to 1 cc/g.
- the base paper after dewatering and drying preferably has a surface roughness Ra of 20 ⁇ m or less, more preferably 10 ⁇ m or less.
- the surface roughness Ra is measured, e.g., with Surtronic 10 from Rank Taylor Hobson.
- the base paper after dewatering and drying preferably has water repellency of 15% or less, more preferably 10% or less.
- the water repellency of base paper is measured, e.g., in accordance with the method specified in JIS P8140, paper and board - determination of water absorptiveness - Cobb method. The contact time between a test piece and water was set at 60 seconds.
- the base sheet after dewatering and drying preferably has a density of 0.62 to 0.9 g/m 3 , more preferably 0.64 to 0.75 g/m 3 . With this density, break of base paper during winding into tubing due to insufficient strength and difficulty in winding due to excessive bending stiffness of base paper are avoided.
- the resulting webs of base paper was each slit into a strip of predetermined width, and the strips are successively lap-wound helically with an overlap between adjacent turns either in the same direction or different directions to be shaped into a tubular form.
- the outer strip When wound in the same direction, the outer strip is preferably wound in a manner to cover the exposed edge of the preceding turns of the inner strip. In lap winding, an adhesive is applied as appropriate to form tubing.
- the width of the strips, the width of overlap, the inner diameter of paper tubing, and the like are decided according to the mass of a casting (i.e., the amount of molten metal passing the paper tube) and required sand-pressure strength of the paper tube (i.e., the strength withstanding the pressure in making a sand mold).
- the tubing After completion of lap-winding all the plies, the tubing is dried by heating at a prescribed temperature and cut to length to complete the production of a part for casting.
- the part for casting of the present embodiment is excellent in that the amount of combustion gas it generates during casting is reduced because of its reduced organic fiber content, and yet it retains good formation.
- the part 10 for casting of the present embodiment generates not more than 250 l/m 2 , preferably not more than 150 l/m 2 , of combustion gas at 1000°C, wherein "m 2 " is the unit of the surface area of the part 10 at an average diameter.
- the term "average diameter” as used herein denotes a diameter calculated by (inner diameter + outer diameter)/2.
- the amount of combustion gas generated is preferably as small as possible.
- the practically reachable lower limit is 1 to 10 l/m 2 .
- the amount of combustion gas generated at 1000°C is measured using equipment for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.).
- the amount of combustion gas generated from base paper is given in cubic centimeter per gram, while that from a part for casting is in liter per square meter. This is because a part having a smaller inner diameter is more liable to cause blowback (back-flow of molten metal) than a part having a larger inner diameter with the base paper making them being equal, i.e., with the amount of gas generation given in cc/g being equal. That is, the amount given in cc/g is not enough to evaluate proneness to blowback. The reason a part with a smaller inner diameter is more prone to cause a blowback is that the volume of molten metal present in a tubular part is relatively smaller and therefore relatively lighter to be blown up than in a larger-diameter tubular part.
- the part for casting according to the present invention enjoys the same advantage of ease of handling as of this type of conventional parts.
- the part for casting is composed of two tubular paper plies, it may be composed of three or more tubular paper plies.
- the ply structure is selected as appropriate to required sand-pressure strength, required high-temperature strength, the thickness of base paper, and so forth.
- high-temperature strength refers to mechanical strength of a part on contact with molten metal.
- the part for casting is formed of base paper previously prepared by a papermaking technique, it is possible to make the part by a conventionally known pulp molding technique using the same raw material slurry as described.
- a sample sheet for evaluation was prepared using the following raw materials of base paper for tubular paper plies.
- the resulting sheet of base paper was evaluated for formation (waviness and disperse state of inorganic powder, etc.), surface roughness, and generation of combustion gas in accordance with the methods described below. The results obtained are shown in Table 1.
- composition of base paper for tubular paper plies Composition of base paper for tubular paper plies (sample for evaluation)
- Inorganic powder obsidian powder (average particle size: 30 ⁇ m) 65.5% by mass
- Inorganic fiber carbon fiber (length: 3 mm; Torayca chopped fiber, available from Toray Industries, Inc.) 4% by mass
- Organic fiber used paper 12% by mass
- Thermosetting resin resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 18% bymass
- Papermaking binder CMC 0.25% by mass (7)
- Dispersant sodium ⁇ -naphthalenesulfonate-formalin condensate (Demol N from Kao Corp.) 0.5% by mass
- the dispersant (8) was added in an amount of 0.5% by mass based on the total (100% by mass) of the components (1) to (7).
- the waviness on the top side (opposite to the wire side) of the sample paper was evaluated by scoring from 1 to 5 based on the number of projections of 1 mm or more in height counted on that side.
- the disperse state of inorganic fibers was evaluated by scoring from 1 to 5 based on the number of flocks of inorganic fibers appearing on the back side (wire side) of sample paper.
- the area ratio of flocks of the inorganic powder and the thermosetting resin was measured on the back side (wire side) of the sample paper and scored for evaluation. When these components are poorly dispersed, they gather on the wire side of paper.
- Flocks of the inorganic powder are recognizable with the naked eye as flocks of whitish powder.
- Flocks of the thermosetting resin are recognizable with the naked eye as flocks of yellow powder.
- the formation was evaluated by the sum of the scores obtained in the evaluations (a) to (c). A higher score means better formation, and a lower score means poor formation.
- the surface roughness Ra was measured with Surtronic 10 from Rank Taylor Hobson in accordance with the operation manual.
- the amount of combustion gas generated was measured using an instrument for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.) as follows.
- the furnace inner temperature was set at 1000°C.
- One-tenth gram (nominal mass) of the sample was weighed out with precision of milligram and placed on the mount of the instrument, and the amount of combustion gas generated was measured in accordance with the instruction manual.
- the amount of combustion gas generated was calculated as programmed based on the integration of the rate of combustion gas generation. Calculation was made based on the amount of combustion gas after an elapse of 30 seconds.
- the rate of combustion gas generation and the amount of combustion gas generated were analyzed on Chromato Pack C-R4A from Shimadz Corp.
- Example 1 A sample sheet of base paper was prepared in the same manner as in Example 1, except for replacing the dispersant of Example 1 with the one described below. The resulting paper was evaluated in the same manner as in Example 1. The results obtained are shown in Table 1.
- Dispersant hydroxypropyl cellulose (Klucel H from Hercules). This dispersant, being sparingly soluble, was preliminarily diluted with water to a 1% concentration and then added to a 0.5% by mass on a solid basis.
- a sample sheet of base paper was prepared in the same manner as in Example 1, except for using no dispersant.
- a sample sheet of base paper was prepared in the same manner as in Example 1, except for using the following raw materials of base paper for tubular paper plies.
- the amount of the organic fiber was doubled, and any dispersant was not added.
- Composition of base paper for tubular paper plies (sample for evaluation) (1) Inorganic powder: obsidian powder (average particle size: 30 ⁇ m) 48% by mass (2) Inorganic fiber: carbon fiber (length: 3 mm; Torayca chopped fiber, available from Toray Industries, Inc.) 9.5% by mass (3) Organic fiber: used paper 24% by mass (4)
- Thermosetting resin resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 18% by mass (5) Papermaking binder: KAIMEN 0.25% by mass (6) Papermaking binder: CMC 0.25% by mass (7) Water repellant not added (8) Dispersant not added Total of (1) to (8): 100% by mass Table 1 Formation Surface Roughness Ra ( ⁇ m) Combustion Gas from Paper (c
- a two-ply tubular part for casting (paper tube) as illustrated in Fig. 1 was formed of base paper having the following composition.
- the resulting part was evaluated for combustion gas generation and blowback in accordance with the method described below. The results obtained are shown in Table 2.
- Inorganic powder obsidian (Nice Catch Flower # 330 from Kinsei Matec Co., Ltd.) 57.3% by mass
- Inorganic fiber carbon fiber (Pyrofil TR03CM from Mitsubishi Chemical Industries, Co., Ltd.) 7.2% by mass
- Organic fiber recycled paper 11.5% by mass
- Thermosetting resin resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 17.5% by mass
- Papermaking binder KAIMEN 3.0% by mass
- Papermaking binder CMC 3.0% by mass
- Water repellant alkyl ketene dimer 0.5% by mass Total of (1) to (7): 100% by mass
- Dispersant sodium ⁇ -naphthalenesulfonate-formalin condensate (DemolN from Kao Corp.) 0.5% by mass
- the dispersant (8) was added in an amount of 0.5% by mass based on the total (100% by mass) of the components (1) to (7).
- Form of part for casting The base paper for tubing (thickness; 0.7 mm) was slit into strips having widths of 80 mm and 82 mm.
- the 80 mm wide strip was spirally lap-wound onto a mandrel having an outer diameter of 50 mm as a first ply.
- the 82 mm wide strip was spirally lap-wound on the first ply while applying an adhesive to the 82 mm wide strip in a manner as to cover the exposed edge of the 80 mm strip to make a paper tube as a part for casting shown in Fig. 1 .
- the amount of combustion gas generated was measured using an instrument for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.) as follows.
- the furnace inner temperature was set at 1000°C.
- One-tenth (0.1) gram (nominal mass) of the sample was weighed out with precision of milligram and placed on the mount of the instrument, and the amount of combustion gas generated was measured in accordance with the instruction manual.
- the amount of combustion gas generated was calculated as programmed based on the integration of the rate of combustion gas generation. Calculation was made based on the amount of combustion gas after an elapse of 30 seconds.
- the rate of combustion gas generation and the amount of combustion gas generated were analyzed on Chromato Pack C-R4A from Shimadz Corp.
- a casting mold 1 illustrated in Fig. 2 was made by burying paper tubes 2 to 4 measuring 50 cm, 30 cm, and 5 cm in length, respectively, all having an inner diameter of 50 mm, connected with pottery elbows, in the cured sand (molding sand) containing a furan resin. Two hundred fifty kilograms of molten metal at 1400°C was poured in the mold through the pour spout 5, and a blowback from the pour spout was observed with the naked eye and rated as follows.
- a two-ply tubular part for casting was made in the same manner as in Example 3, except that base paper was prepared using the following composition (the amount of the organic fibers was doubled, and any dispersant was not used).
- the resulting part for casting was evaluated in the same manner as in Example 3. The results are shown in Table 2.
- the present invention provides a part for casting which has a reduced content of organic fibers while retaining excellent formation so as to reduce generation of combustion gas during casting.
- the invention also provides a process for advantageously making a part for casting having the above effects.
- the present invention is applicable to various casting mold parts constituting a casting mold, such as a pouring cup, a runner, a gate, a gas vent, a feeder, and a mold cavity, and production of such parts.
Description
- The present invention relates to a part for producing castings (hereinafter "part for casting" or simply "part") that can be use as a runner, etc. in the production of castings and a process of making the part.
- Applicant has proposed in
JP 2004-174605A - It is desirable that such a part for casting containing organic fiber, inorganic fiber, and a binder has a minimized content of the organic fiber in order to reduce the generation of combustion gas (hereinafter sometimes referred simply to as "gas") accompanying thermal decomposition of the organic fiber during casting. If the organic fiber content is reduced, however, the components will have poor dispersibility, tending to result in poor formation to yield a high proportion of defective castings. In the case of making base paper by papermaking, in particular, reduction in organic fiber content is liable to produce wavy paper.
- The present invention relates to a satisfactory part for casting and a process of producing the part, in which a specific dispersant is used to allow for reducing an organic fiber content. The invention also relates to a satisfactory part for casting having a reduced organic fiber content and a process of producing the part.
- The present inventors have found that a satisfactory part for casting can be obtained by using a specific dispersant even when an organic fiber content is reduced and completed the invention.
- Based on the above finding, the present invention provides a process of producing a part for casting including the step of preparing a raw material slurry containing inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant.
- The present invention also provides a part for casting containing inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant.
-
-
Fig. 1 is a schematic perspective of an embodiment of the present invention. -
Fig. 2 is a cross-section schematically illustrating a casting mold that is used to evaluate blowback in Examples. - The present invention will be described based on its preferred embodiments with reference to the accompanying drawings.
- The part for casting according to the invention is first described based on its preferred embodiment. The
part 10 of the embodiment shown inFig. 1 contains inorganic powder, inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a water repellant and, in addition, 0.001% to 10% by mass, preferably 0.01% to 10% by mass, of a sulfonate-based and/or a cellulose-based dispersant based on 100% by mass of the total of the inorganic powder, inorganic fibers, organic fibers, thermosetting resin, papermaking binder, and water repellant. Use of such amount of a dispersant enables production of a good part while minimizing the content of the organic fibers. - Examples of the sulfonate-based dispersant include a sodium β-naphthalenesulfonate-formalin condensate, sodium ligninsulfonate, a sodium melaminesulfonate-formalin condensate, an aromatic aminosulfonic acid sodium salt polymer, sodium polystyrenesulfonate, a styrenesulfonic acid-sodium maleinsulfonate copolymer, sodium polycyclopentadienesulfonate, and an aliphatic dienesulfonic acid sodium salt polymer. Preferred of them is a sodium β-naphthalenesulfonate-formalin condensate having a degree of polycondensation of 3 to 6 for consideration of the formation of wet base paper (a wet mat of fiber).
- The cellulose-based dispersant preferably has high water solubility and preferably dissolves completely in a 1% by mass aqueous solution. Such a cellulose-based dispersant is exemplified by cellulose propylene oxide adduct derivatives, e.g., hydroxypropyl cellulose and hydroxypropylmethyl cellulose. Hydroxypropyl cellulose is preferred for consideration of the formation of wet base paper (a wet fiber mat).
- The dispersants can be used either individually or as a combination of two or more thereof.
- The ratio of the inorganic powder/inorganic fibers/organic fibers/thermosetting resin (solid content)/papermaking binder (solid content)/water repellant in the part for casting of the invention is 0-70%/1-60%/1-40%/1-40%/1-10%/0-5% by mass, preferably 40-70%/1-10%/1-25%/1-25%/1-10%/0-5% by mass, more preferably 50-70%/1-8%/1-20%/10-25%/3-7%/0-1% by mass, taking the total of these components as 100% by mass. The content of the inorganic powder being within the range recited, the part has good shape retention during pouring, and a fiber molded article has good surface conditions and good release from a mold. With the content of the inorganic fibers being within the range recited, good papermaking properties and good shape retention during pouring are obtained. With the organic fiber content being in the range recited, good papermaking properties are obtained, and combustion gas generation during pouring can be held down so as to prevent a blowback (a back-flow of molten metal). The thermosetting resin content falling in that range, the casting mold has good molding properties, and a fiber molded article has good shape retention after pouring and good surface smoothness. The papermaking binder content being in that range, the binder makes the powder component in the slurry cling to the fibers while causing the fibers to moderately intermingle with one another to form flocks optimum for sheet formation and thereby securing good yield. With the water repellant content being in the range recited, the base paper formed by papermaking can be converted into a part for casting with a minimum amount of an adhesive because the adhesive applied is prevented from penetrating into the base paper. Furthermore, after the part for casting is buried in molding sand, the water content of the molding sand is prevented from penetrating into the part.
- Examples of the inorganic powder include obsidian, mullite, and graphite including flaky graphite and earthy graphite. One or more than one kind of the inorganic powders can be selected for use. In the case where a casting has a carbon content of 4.2% by mass or less, carburizing (penetration of carbon into a casting to make the casting brittle) occurs. In that case, inorganic powder having a silica content should be used to prevent carburizing from a casting carbide. It is preferred to use obsidian, mullite, etc. as an inorganic powder. When the carbon content of the casting is 4.2% by mass or more, the part does not need to contain inorganic powder.
- The inorganic fiber serves mainly to constitute the skeleton of the part. For example, it does not burn even with the heat of molten metal and continues serving to retain the shape of the part during casting. Examples of the inorganic fiber include artificial mineral fibers, such as carbon fiber and rock wool, ceramic fibers, and natural mineral fibers. They can be used either alone or in combination of two or more thereof. Carbon fiber that maintains high strength even in high temperatures, such as pitch-based carbon fiber or polyacrylonitrile (PAN)-based carbon fiber, is preferred for effectively reducing thermal shrinkage accompanying carbonization of the thermosetting resin. PAN-based carbon fiber is especially preferred.
- The inorganic fiber preferably has an average length of 0.1 to 10 mm, more preferably 0.5 to 8 mm, in view of the quality of a fiber molded product obtained by papermaking technique. Continuous fibers of 10 mm or longer may be used as cut in a slurry in a refiner, etc. to have an average fiber length controlled to 0.1 to 10 mm.
- Examples of the organic fibers include pulp fibers, fibrillated synthetic fibers, and regenerated fibers (e.g., rayon fiber). These fibers are used either individually or as a mixture of two or more thereof. Preferred of them is pulp fiber from the viewpoint of sheet forming properties, strength after drying, and cost.
- Examples of the pulp fibers include not only wood pulp but non-wood pulp, such as cotton pulp, linter pulp, bamboo, and straw. These kinds of pulp, whether virgin or recycled, can be used either alone or in combination thereof. From the standpoint of availability, environmental conservation, and reduction of production cost, used paper pulp is preferred.
- It is preferred for the organic fibers to have an average length of 0.1 to 20 mm, more preferably 0.5 to 10 mm, from the viewpoint of surface smoothness and impact strength of the resulting base sheet.
- The thermosetting resin is a component necessary to retain the low- and high-temperature strength of the
part 10 and to provide a paper tube with good surface properties which contribute to improve the surface smoothness of a casting. The thermosetting resins include phenol resins, epoxy resins, and furan resins. Phenol resins are preferred in view of reduced generation of combustible gas, resistance to burning, and a high carbon residue content after thermal decomposition (carbonization) as high as 25% or more to form a carbonized film to provide a casting with an improved casting surface. As used herein the terms "carbon residue content" refers to a value obtained by heating a thermosetting resin sample in a nitrogen atmosphere from room temperature up to 1200°C at a rate of temperature rise of 50°C/min, measuring the mass of the residue, and dividing the mass of the residue with the mass before heating. The mass after heating is lighter than that before heating because combustion gas is released from the resin during heating. Usable phenol resins include novolak phenol resins requiring a curing agent and resol type phenol resins requiring no curing agent. In order to minimize elution of free phenol into white water, it is preferred to use a low-release phenol resin, such as high-molecular-weight resol phenol resins synthesized using a basic catalyst or an acidic catalyst. In using a novolak phenol resin, a curing agent is needed. Since the curing agent easily dissolves in water, it is preferably applied to the surface of a dewatered fiber mat. Preferred examples of the curing agent include hexamethylenetetramine. The thermosetting resins can be used either individually or as a combination of two or more thereof. - Examples of the combustion gas include carbon monoxide, carbon dioxide, and hydrocarbons such as methane and ethylene.
- Examples of the papermaking binder include natural polymers such as starch, gelatin, guar gum, and carboxymethyl cellulose (CMC); water soluble synthetic polymers such as KAIMEN (polyamideamine-epichlorohydrin resin), polyvinyl alcohol (PVA), polyacrylamide (PAM), and polyethylene oxide (PEO); styrene-butadiene latices, acrylonitrile-butadiene latices, acrylic latices, and vinyl acetate latices; and inorganic binders such as colloidal silica and alumina-based binders. Preferred of them are KAIMEN, CMC, and acrylic latices for their powder-fixing properties. The papermaking binder is preferably used in an amount of 0.01% to 5%, more preferably 0.02% to 1%, on a solid basis based on the mass of the organic fibers. These papermaking binders can be used either individually or as a combination of two or more thereof.
- The
part 10 can contain a water repellant to prevent penetration of the adhesive described supra into base paper and to prevent loss of strength due to moisture absorption. Silicone surface active agents, fluorine-containing surface active agents, fat and oil type surface active agents, hydrophobic surface active agents, and hydrophobic polymers can be used as a water repellant. The water repellant is preferably applied to both the inner and outer sides of thepart 10 and dried to prevent deterioration of strength due to moisture absorption. The water repellant is advisably used in the form of an aqueous solution or emulsion that is convenient to handle upon use. The water repellants may be used either individually or as a combination of two or more thereof. Silicone, fluorine-containing or fat and oil type emulsions are preferably used. When the water repellant is added to a slurry, particularly preferred is an alkyl ketene dimer (AKD), which exhibits excellent water repellency in a neutral region at a small amount and is superior in acid resistance and alkali resistance to rosin, etc. The water repellant may be added in an adequate amount to a raw material slurry or applied to the part. Coating techniques include spraying, brush coating, dipping, and pouring. Spraying, dipping or pouring is preferred for productivity. Coating by "pouring" as used here is achieved by hosing a pumped liquid over the part to be coated. In cases where the part for casting is used in a dry working environment or when the thermosetting resin serves for water repellency depending on its kind or amount used, the water repellant may be dispensed with. - The
part 10 may contain other components such as a flocculant and a colorant in appropriate amounts in addition to the above described components. - The
part 10 preferably has a surface roughness Ra of 20 µm or less, more preferably 10 µm or less. The surface roughness Ra is measured, e.g., withSurtronic 10 from Rank Taylor Hobson. - The
part 10 is preferably formed of base paper containing the aforementioned components. The base paper preferably has a tensile strength of 40 N/15 mm or more, more preferably 80 N/15 mm or more. The tensile strength is measured in a tensile test of a 15 mm wide specimen cut out of 0.7 mm thick base paper on a Tensilon universal tester RTA500 from A & D Co., Ltd. When the thickness of a sample is not 0.7 mm, the tensile strength as measured is converted to strength per unit cross-sectional area for comparison. Base paper having a tensile strength within the above range does not tear or break when spirally wound to make paper tubing as a part for casting as in the present embodiment. - To secure strength, the
part 10 preferably has a compressive strength of 20 N or higher, more preferably 40 N or higher, before use in casting. The term "compressive strength" as used herein is a compressive strength of the wall of tubing measured as follows. A 60 mm wide specimen cut out of a part for casting is set on a compressive strength testing instrument (e.g., a Tensilon universal tester RTA 500 from A & D) with its cut area horizontal and compressed at a rate of 10 mm/min. - While the thickness of the
part 10 is subject to variation according to where it is applied, it is preferably 0.5 to 6 mm, more preferably 1 to 3 mm, for securing strength required of a part for casting and air permeability and reducing the production cost. - It is preferred for the
part 10 before use in casting to have a water content of not more than 20% by mass, more preferably 10% by mass or less, to minimize water vapor generation on contact with molten metal. Water vapor generation causes blowback (back flow) of molten metal from the pour spout. - A preferred embodiment of the process of producing a part for casting according to the present invention will then be described with reference to the production of the
part 10. - The
part 10 is composed of two tubular paper plies 11 and 12 each formed of spirally wound base paper. The production of thepart 10 starts with preparation of base paper for making the tubular paper plies 11 and 12. - Respective raw material slurries for the base paper for making the tubular paper plies 11 and 12 are prepared from the above-described inorganic powder, inorganic fibers, organic fibers, thermosetting resin, papermaking binder, and dispersant. Each of the slurries is converted to a sheet form (wet fiber mat), dewatered, and dried in accordance with a wet papermaking technique to obtain base paper.
- Examples of the dispersing medium of the slurry include water, white water, and solvents such as ethanol and methanol. Water is preferred in view of stability in wet fiber mat formation and dewatering, stability of quality of the resulting base paper, cost, and ease of handling.
- If desired, the slurry can contain additives including a flocculant and an antiseptic.
- The slurry thus prepared is then converted into base paper for making paper tubing by a papermaking process.
- Papermaking can be carried out by any technique selected from, for example, continuous papermaking methods using a cylinder paper machine, a Fourdrinier paper machine, a short-wire paper machine or a twin-wire paper machine, and batchwise papermaking methods including manual papermaking.
- In order for the base paper to keep the shape retention and mechanical strength after papermaking, the wet fiber mat is dewatered to reduce its water content preferably to 30% or smaller, more preferably to 10% or smaller. Dewatering of the fiber layer can be conducted by, for example, suction, blowing pressurized air or pressing with a pressure roll or a pressure plate.
- The dewatered fiber mat is forwarded to a drying step. Any means for drying that has conventionally been used to dry paper can be used in the drying step.
- The base paper after dewatering and drying preferably has a tensile strength of 40 N/15 mm or more, more preferably 80 N/15 mm, to be wound into tubing. The tensile strength .is measured in a tensile test of a 15 mm wide specimen cut out of 0.7 mm thick base paper on the above mentioned Tensilon universal tester. When the thickness of samples to be measured is not 0.7 mm, the tensile strength as measured is converted to strength per unit cross-sectional area for comparison.
- The base paper after dewatering and drying preferably has a buckling strength of 3 N or higher, more preferably 4 N or higher, in view of the strength of the resulting part for casting. The buckling strength is measured by a 3-point bending test as follows. A specimen of base sheet measuring 60 mm in width and 100 mm in length is set on a tester with a 40 mm span length, and compressed from above by an indenter having a width of 60 mm and a diameter of 6 mm at the tip. From the same viewpoint, the base paper after dewatering and drying preferably has a buckling displacement of 3 mm or more, more preferably 5 mm or more. The term "buckling displacement" means the amount of displacement of base paper at the maximum stress point in the above described 3-point bending test.
- It is preferred that the base paper after dewatering and drying generates not more than 250 cc/g, more preferably not more than 200 cc/g, of combustion gas per unit mass of the part at 1000°C. The amount of combustion gas generated is measured using equipment for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.). The amount of combustion gas generated is preferably as small as possible. The practically reachable lower limit is 0.1 to 1 cc/g.
- The base paper after dewatering and drying preferably has a surface roughness Ra of 20 µm or less, more preferably 10 µm or less. The surface roughness Ra is measured, e.g., with
Surtronic 10 from Rank Taylor Hobson. - In the case where the water repellant is used, the base paper after dewatering and drying preferably has water repellency of 15% or less, more preferably 10% or less. The water repellency of base paper is measured, e.g., in accordance with the method specified in JIS P8140, paper and board - determination of water absorptiveness - Cobb method. The contact time between a test piece and water was set at 60 seconds.
- The base sheet after dewatering and drying preferably has a density of 0.62 to 0.9 g/m3, more preferably 0.64 to 0.75 g/m3. With this density, break of base paper during winding into tubing due to insufficient strength and difficulty in winding due to excessive bending stiffness of base paper are avoided.
- The resulting webs of base paper was each slit into a strip of predetermined width, and the strips are successively lap-wound helically with an overlap between adjacent turns either in the same direction or different directions to be shaped into a tubular form. When wound in the same direction, the outer strip is preferably wound in a manner to cover the exposed edge of the preceding turns of the inner strip. In lap winding, an adhesive is applied as appropriate to form tubing. The width of the strips, the width of overlap, the inner diameter of paper tubing, and the like are decided according to the mass of a casting (i.e., the amount of molten metal passing the paper tube) and required sand-pressure strength of the paper tube (i.e., the strength withstanding the pressure in making a sand mold).
- After completion of lap-winding all the plies, the tubing is dried by heating at a prescribed temperature and cut to length to complete the production of a part for casting.
- The part for casting of the present embodiment is excellent in that the amount of combustion gas it generates during casting is reduced because of its reduced organic fiber content, and yet it retains good formation.
- The
part 10 for casting of the present embodiment generates not more than 250 l/m2, preferably not more than 150 l/m2, of combustion gas at 1000°C, wherein "m2" is the unit of the surface area of thepart 10 at an average diameter. The term "average diameter" as used herein denotes a diameter calculated by (inner diameter + outer diameter)/2. The amount of combustion gas generated is preferably as small as possible. The practically reachable lower limit is 1 to 10 l/m2. The amount of combustion gas generated at 1000°C is measured using equipment for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.). - As understood from the above description, the amount of combustion gas generated from base paper is given in cubic centimeter per gram, while that from a part for casting is in liter per square meter. This is because a part having a smaller inner diameter is more liable to cause blowback (back-flow of molten metal) than a part having a larger inner diameter with the base paper making them being equal, i.e., with the amount of gas generation given in cc/g being equal. That is, the amount given in cc/g is not enough to evaluate proneness to blowback. The reason a part with a smaller inner diameter is more prone to cause a blowback is that the volume of molten metal present in a tubular part is relatively smaller and therefore relatively lighter to be blown up than in a larger-diameter tubular part.
- In addition to the above, being light-weight and easy to cut to length with a convenient device, the part for casting according to the present invention enjoys the same advantage of ease of handling as of this type of conventional parts.
- The present invention is not limited to the foregoing embodiments, and various changes and modifications can be made therein without departing from the spirit and scope thereof.
- For example, while in the foregoing embodiments the part for casting is composed of two tubular paper plies, it may be composed of three or more tubular paper plies. The ply structure is selected as appropriate to required sand-pressure strength, required high-temperature strength, the thickness of base paper, and so forth. The term "high-temperature strength" as used herein refers to mechanical strength of a part on contact with molten metal.
- While in the foregoing embodiments the part for casting is formed of base paper previously prepared by a papermaking technique, it is possible to make the part by a conventionally known pulp molding technique using the same raw material slurry as described.
- The present invention will now be illustrated in greater detail with reference to Examples, but it should be understood that the invention is not limited thereto. Unless otherwise noted, all the percents are by mass.
- A sample sheet for evaluation was prepared using the following raw materials of base paper for tubular paper plies. The resulting sheet of base paper was evaluated for formation (waviness and disperse state of inorganic powder, etc.), surface roughness, and generation of combustion gas in accordance with the methods described below. The results obtained are shown in Table 1.
- Composition of base paper for tubular paper plies (sample for evaluation)
(1) Inorganic powder: obsidian powder (average particle size: 30 µm) 65.5% by mass (2) Inorganic fiber: carbon fiber (length: 3 mm; Torayca chopped fiber, available from Toray Industries, Inc.) 4% by mass (3) Organic fiber: used paper 12% by mass (4) Thermosetting resin: resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 18% bymass (5) Papermaking binder: KAIMEN 0.25% by mass (6) Papermaking binder: CMC 0.25% by mass (7) Water repellant not added Total of (1) to (7): 100% by mass (8) Dispersant: sodium β-naphthalenesulfonate-formalin condensate (Demol N from Kao Corp.) 0.5% by mass - The dispersant (8) was added in an amount of 0.5% by mass based on the total (100% by mass) of the components (1) to (7).
- In a 2-liter juicer-mixer were put 100 g, in total, of the components (1) to (7) and 0.5 g of the dispersant (8) in accordance with the composition above together with 1.9 liters of water and agitated for 3 minutes to prepare a stock slurry. The stock slurry was poured into a papermaking tester (size of paper made: 250 mm (W) x 250 mm (L); wire: 40 mesh; capacity: 15 liters) together with 13-liter of diluted water, stirred, and allowed to stand for 1 minute. White water was drained through the wire to form a wet fiber mat, which was pressed under 0.1 MPa and dried in a dryer at 105°C for 30 minutes to obtain a sample sheet of base paper.
- The waviness on the top side (opposite to the wire side) of the sample paper was evaluated by scoring from 1 to 5 based on the number of projections of 1 mm or more in height counted on that side.
- Scoring system:
- 0: 50 or more projections
- 1: 40 to 49 projections
- 2: 30 to 39 projections
- 3: 20 to 29 projections
- 4: 10 to 19 projections
- 5: 9 or less projections
- The disperse state of inorganic fibers was evaluated by scoring from 1 to 5 based on the number of flocks of inorganic fibers appearing on the back side (wire side) of sample paper.
- 0: 50 or more flocks of carbon fibers
- 1: 40 to 49 flocks of carbon fibers
- 2: 30 to 39 flocks of carbon fibers
- 3: 20 to 29 flocks of carbon fibers
- 4: 10 to 19 flocks of carbon fibers
- 5: 9 or less flocks of carbon fibers
- The area ratio of flocks of the inorganic powder and the thermosetting resin was measured on the back side (wire side) of the sample paper and scored for evaluation. When these components are poorly dispersed, they gather on the wire side of paper.
- 0: the area ratio of the inorganic powder and thermosetting resin flocks is 80% to 100%.
- 1: the area ratio of the inorganic powder and thermosetting resin flocks is 60% to 79%.
- 2: the area ratio of the inorganic powder and thermosetting resin flocks is 40% to 59%.
- 3: the area ratio of the inorganic powder and thermosetting resin flocks is 20% to 39%.
- 4: the area ratio of the inorganic powder and thermosetting resin flocks is 10% to 19%.
- 5: the area ratio of the inorganic powder and thermosetting resin flocks is 9% or less.
- Flocks of the inorganic powder are recognizable with the naked eye as flocks of whitish powder. Flocks of the thermosetting resin are recognizable with the naked eye as flocks of yellow powder.
- The formation was evaluated by the sum of the scores obtained in the evaluations (a) to (c). A higher score means better formation, and a lower score means poor formation.
- The surface roughness Ra was measured with
Surtronic 10 from Rank Taylor Hobson in accordance with the operation manual. - The amount of combustion gas generated was measured using an instrument for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.) as follows. The furnace inner temperature was set at 1000°C. One-tenth gram (nominal mass) of the sample was weighed out with precision of milligram and placed on the mount of the instrument, and the amount of combustion gas generated was measured in accordance with the instruction manual. The amount of combustion gas generated was calculated as programmed based on the integration of the rate of combustion gas generation. Calculation was made based on the amount of combustion gas after an elapse of 30 seconds. The rate of combustion gas generation and the amount of combustion gas generated were analyzed on Chromato Pack C-R4A from Shimadz Corp.
- A sample sheet of base paper was prepared in the same manner as in Example 1, except for replacing the dispersant of Example 1 with the one described below. The resulting paper was evaluated in the same manner as in Example 1. The results obtained are shown in Table 1.
Dispersant: hydroxypropyl cellulose (Klucel H from Hercules). This dispersant, being sparingly soluble, was preliminarily diluted with water to a 1% concentration and then added to a 0.5% by mass on a solid basis. - A sample sheet of base paper was prepared in the same manner as in Example 1, except for using no dispersant.
- The resulting paper was evaluated in the same manner as in Example 1. The results obtained are shown in Table 1.
- A sample sheet of base paper was prepared in the same manner as in Example 1, except for using the following raw materials of base paper for tubular paper plies. In Comparative Example 2, the amount of the organic fiber was doubled, and any dispersant was not added.
Composition of base paper for tubular paper plies (sample for evaluation)(1) Inorganic powder: obsidian powder (average particle size: 30 µm) 48% by mass (2) Inorganic fiber: carbon fiber (length: 3 mm; Torayca chopped fiber, available from Toray Industries, Inc.) 9.5% by mass (3) Organic fiber: used paper 24% by mass (4) Thermosetting resin: resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 18% by mass (5) Papermaking binder: KAIMEN 0.25% by mass (6) Papermaking binder: CMC 0.25% by mass (7) Water repellant not added (8) Dispersant not added Total of (1) to (8): 100% by mass Table 1 Formation Surface Roughness Ra (µm) Combustion Gas from Paper (cc/g) Waviness Dispersed State Overall Judgement Inorganic Powder Inorganic Fiber Thermosetting Resin Example 1 4 4 4 5 17 4.2 190 Example 2 5 5 4 5 19 9.5 198 Comp. Example 1 1 2 2 2 7 23.8 202 Comp. Example 2 5 4 5 5 19 8.0 268 - As is apparent from Table 1, the base paper obtained in each Example was proved better in formation and surface roughness and to generate a reduced amount of combustion gas as compared with that of Comparative Example 1. In Comparative Example 2, base paper with good formation and surface roughness was obtained owing to the use of double the amount of organic fibers used in Example 1 but, in turn, produced an increased amount of combustion gas.
- A two-ply tubular part for casting (paper tube) as illustrated in
Fig. 1 was formed of base paper having the following composition. The resulting part was evaluated for combustion gas generation and blowback in accordance with the method described below. The results obtained are shown in Table 2. - Composition of base paper for paper tube
(1) Inorganic powder: obsidian (Nice Catch Flower # 330 from Kinsei Matec Co., Ltd.) 57.3% by mass (2) Inorganic fiber: carbon fiber (Pyrofil TR03CM from Mitsubishi Chemical Industries, Co., Ltd.) 7.2% by mass (3) Organic fiber: recycled paper 11.5% by mass (4) Thermosetting resin: resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 17.5% by mass (5) Papermaking binder: KAIMEN 3.0% by mass (6) Papermaking binder: CMC 3.0% by mass (7) Water repellant: alkyl ketene dimer 0.5% by mass Total of (1) to (7): 100% by mass (8) Dispersant: sodium β-naphthalenesulfonate-formalin condensate (DemolN from Kao Corp.) 0.5% by mass - The dispersant (8) was added in an amount of 0.5% by mass based on the total (100% by mass) of the components (1) to (7).
- In a 2-liter juicer-mixer were put 100 g, in total, of the components (1) to (7) and 0.5 g of the dispersant (8) in accordance with the composition above together with 1.9 liters of water and agitated for 3 minutes to prepare a stock slurry. The stock slurry was poured into a papermaking tester (size of paper made: 250 mm (W) x 250 mm (L); wire: 40 mesh; capacity: 15 liters) together with 13-liter of diluted water, stirred, and allowed to stand for 1 minute. White water was drained through the wire to form a wet fiber mat, which was pressed under 0.1 MPa and dried in a dryer at 105°C for 30 minutes to obtain a sample sheet of base paper.
- Form of part for casting:
The base paper for tubing (thickness; 0.7 mm) was slit into strips having widths of 80 mm and 82 mm. The 80 mm wide strip was spirally lap-wound onto a mandrel having an outer diameter of 50 mm as a first ply. The 82 mm wide strip was spirally lap-wound on the first ply while applying an adhesive to the 82 mm wide strip in a manner as to cover the exposed edge of the 80 mm strip to make a paper tube as a part for casting shown inFig. 1 . - Adhesive: phenol resin emulsion (PR-51464 from Sumitomo Bakelite Co., Ltd.)
- Total thickness: 1.4 mm
- Inner diameter: 50 mm
- The amount of combustion gas generated was measured using an instrument for measuring the amount of generated combustion gas (No. 682 Gas Pressure Tester from Harry W. Dietert Co.) as follows. The furnace inner temperature was set at 1000°C. One-tenth (0.1) gram (nominal mass) of the sample was weighed out with precision of milligram and placed on the mount of the instrument, and the amount of combustion gas generated was measured in accordance with the instruction manual. The amount of combustion gas generated was calculated as programmed based on the integration of the rate of combustion gas generation. Calculation was made based on the amount of combustion gas after an elapse of 30 seconds. The rate of combustion gas generation and the amount of combustion gas generated were analyzed on Chromato Pack C-R4A from Shimadz Corp.
- A casting
mold 1 illustrated inFig. 2 was made by buryingpaper tubes 2 to 4 measuring 50 cm, 30 cm, and 5 cm in length, respectively, all having an inner diameter of 50 mm, connected with pottery elbows, in the cured sand (molding sand) containing a furan resin. Two hundred fifty kilograms of molten metal at 1400°C was poured in the mold through the pourspout 5, and a blowback from the pour spout was observed with the naked eye and rated as follows. - good: a slight flame generated
- bad: an about one-meter column of flame generated
- A two-ply tubular part for casting (paper tube) was made in the same manner as in Example 3, except that base paper was prepared using the following composition (the amount of the organic fibers was doubled, and any dispersant was not used). The resulting part for casting was evaluated in the same manner as in Example 3. The results are shown in Table 2.
- Composition of base paper for paper tube
(1) Inorganic powder: mullite (Mullite MM#200 from MC Kosan K.K.) 47.6% by mass (2) Inorganic fiber: carbon fiber (Pyrofil TR03CM from Mitsubishi Chemical Industries, Co., Ltd.) 4.2% by mass (3) Organic fiber: recycled paper 25.0% by mass (4) Thermosetting resin: resol phenol resin (Bellpearl S-890 from Air Water Bellpearl Inc.) 16.7% by mass (5) Papermaking binder: KAIMEN 3.0% by mass (6) Papermaking binder: CMC 3.0% by mass (7) Water repellant: alkyl ketene dimer 0.5% by mass Total of (1) to (7): 100% by mass Table 2 Combustion Gas from Paper (cc/g) Combustion Gas from Part for Casting (l/m2) Blowback Example 3 230 225.0 good Comparative Example 3 260 315.8 bad - As can be seen from Table 2, the parts for casting obtained in Example show a reduction of combustion gas generation and prevent a blowback.
- The present invention provides a part for casting which has a reduced content of organic fibers while retaining excellent formation so as to reduce generation of combustion gas during casting. The invention also provides a process for advantageously making a part for casting having the above effects.
- The present invention is applicable to various casting mold parts constituting a casting mold, such as a pouring cup, a runner, a gate, a gas vent, a feeder, and a mold cavity, and production of such parts.
Claims (13)
- A process of producing a part for casting comprising the step of preparing a raw material slurry comprising inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant.
- The process of producing a part for casting according to claim 1, wherein the raw material slurry further comprises an inorganic powder and/or a water repellant.
- The process of producing a part for casting according to claim 2, wherein the mass content of the inorganic powder is 0% to 70%, the mass content of the inorganic fibers is 1% to 60%, the mass content of the organic fibers is 1% to 40%, the mass content of the thermosetting resin is 1% to 40%, the mass content of the papermaking binder is 1% to 10%, and the mass content of the water repellant is 0% to 5%, the total of the inorganic powder, the inorganic fibers, the organic fibers, the thermosetting resin, the papermaking binder, and the water repellant being 100%.
- The process of producing a part for casting according to any one of claims 1 to 3, wherein the sulfonate-based dispersant is a sodium β-naphthalenesulfonate-formalin condensate having a degree of polycondensation of 3 to 6.
- The process of producing a part for casting according to any one of claims 1 to 3, wherein the cellulose-based dispersant is a propylene oxide adduct derivative of cellulose.
- The process of producing a part for casting according to any one of claims 2 to 4, wherein the raw material slurry contains at least one of obsidian, mullite, and graphite as the inorganic powder, at least one of carbon fiber, rock wool, and ceramic fiber as the inorganic fibers, and at least one of a phenol resin, an epoxy resin, and a furan resin as the thermosetting resin.
- A part for casting comprising inorganic fibers, organic fibers, a thermosetting resin, a papermaking binder, and a sulfonate-based and/or a cellulose-based dispersant.
- The part for casting according to claim 7, which generates not more than 250 l/m2 of combustion gas at 1000°C.
- The part for casting according to claim 7 or 8, which further comprises an inorganic powder and/or a water repellant.
- The part for casting according to claim 9, wherein the mass content of the inorganic powder is 0% to 70%, the mass content of the inorganic fibers is 1% to 60%, the mass content of the organic fibers is 1% to 40%, the mass content of the thermosetting resin is 1% to 40%, the mass content of the papermaking binder is 1% to 10%, and the mass content of the water repellant is 0% to 5%, the total of the inorganic powder, the inorganic fibers, the organic fibers, the thermosetting resin, the papermaking binder, and the water repellant being 100%.
- The part for casting according to any one of claims 7 to 10, wherein the sulfonate-based dispersant is a sodium β-naphthalenesulfonate-formalin condensate having a degree of polycondensation of 3 to 6.
- The part for casting according to any one of claims 7 to 10, wherein the cellulose-based dispersant is a propylene oxide adduct derivative of cellulose.
- The part for casting according to any one of claims 9 to 12, wherein the raw material slurry contains at least one of obsidian, mullite, and graphite as the inorganic powder, at least one of carbon fiber, rock wool, and ceramic fiber as the inorganic fibers, and at least one of a phenol resin, an epoxy resin, and a furan resin as the thermosetting resin.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2005346813 | 2005-11-30 | ||
JP2005346814 | 2005-11-30 | ||
PCT/JP2006/323797 WO2007063888A1 (en) | 2005-11-30 | 2006-11-29 | Component for casting production and method for producing same |
Publications (3)
Publication Number | Publication Date |
---|---|
EP1958717A1 EP1958717A1 (en) | 2008-08-20 |
EP1958717A4 EP1958717A4 (en) | 2011-04-13 |
EP1958717B1 true EP1958717B1 (en) | 2019-01-09 |
Family
ID=38092221
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP06833601.5A Expired - Fee Related EP1958717B1 (en) | 2005-11-30 | 2006-11-29 | Component for casting production and method for producing same |
Country Status (5)
Country | Link |
---|---|
US (1) | US20090211717A1 (en) |
EP (1) | EP1958717B1 (en) |
KR (1) | KR101205749B1 (en) |
CN (1) | CN101316665B (en) |
WO (1) | WO2007063888A1 (en) |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP4002200B2 (en) * | 2002-03-13 | 2007-10-31 | 花王株式会社 | Papermaking parts for casting production |
JP5680490B2 (en) * | 2010-06-25 | 2015-03-04 | 花王株式会社 | Casting structure |
CN104884186B (en) * | 2012-12-28 | 2017-09-26 | 花王株式会社 | The structures such as the manufacture method and casting mold of structure for casting production |
CN104338892A (en) * | 2013-07-31 | 2015-02-11 | 见得行股份有限公司 | Stabilizing agent added to green sand mold |
CN104943243A (en) * | 2015-06-19 | 2015-09-30 | 姚伟 | Preparation process of paper pouring earthenware pipe |
CN104985109A (en) * | 2015-07-06 | 2015-10-21 | 安徽三联泵业股份有限公司 | Modified casting sand used for casting pump body and adopting furan resin loaded with carbon nanometer fibers |
CN105834367A (en) * | 2016-05-13 | 2016-08-10 | 湖州炜炎环保科技有限公司 | Technology for manufacturing paper pouring gate pipe for casting |
TWI630041B (en) * | 2017-05-09 | 2018-07-21 | 皇廣鑄造發展股份有限公司 | Runner protection tube for casting and manufacturing method thereof |
CN108296424B (en) * | 2017-09-27 | 2020-04-10 | 柳州市柳晶科技股份有限公司 | 3D printing precoated sand prepared by taking cellulose as adhesive |
CN110170611A (en) * | 2019-04-03 | 2019-08-27 | 张储 | A kind of casting fibrous type casing forming technique |
Family Cites Families (70)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1941277A (en) * | 1930-08-14 | 1933-12-26 | Burgess Lab Inc C F | Manufacture of ether derivatives of carbohydrates like cellulose |
US1925584A (en) * | 1932-06-25 | 1933-09-05 | Richardson Co | Production of pulps containing thermoplastic substances |
US2006392A (en) * | 1933-04-10 | 1935-07-02 | Carey Philip Mfg Co | Material and article containing fiber and method of making the same |
US2269455A (en) * | 1940-02-17 | 1942-01-13 | Castings Patent Corp | Mold and sprue sleeve therefor |
US2523377A (en) * | 1946-12-24 | 1950-09-26 | Hercules Powder Co Ltd | Preparation of cellulose ethers |
US2626213A (en) * | 1948-12-21 | 1953-01-20 | Raybestos Manhattan Inc | Asbestos dispersions and method of forming same |
NL97152C (en) * | 1950-02-09 | |||
US2772603A (en) * | 1950-09-12 | 1956-12-04 | Owens Corning Fiberglass Corp | Fibrous structures and methods for manufacturing same |
US2807543A (en) * | 1954-01-18 | 1957-09-24 | Raymond C Mcquiston | Method of preparing fiber dispersions containing an elastomeric binder |
US2962415A (en) * | 1956-03-05 | 1960-11-29 | Hurlbut Paper Company | Specialty papers containing a resin dispersant and retention aid and process for producing the same |
US2962414A (en) * | 1956-03-05 | 1960-11-29 | Hurlbut Paper Company | High strength specialty papers and processes for producing the same |
US2906660A (en) * | 1956-04-17 | 1959-09-29 | American Mach & Foundry | Glass fiber dispersions, sheets, plastic impregnated sheets and methods of forming |
US2971844A (en) * | 1959-06-29 | 1961-02-14 | Bosanac Beatrice | Method for preparing linden blossom tea concentrate |
US3116199A (en) * | 1961-07-19 | 1963-12-31 | Fmc Corp | Water-laid web |
US3236719A (en) * | 1961-08-14 | 1966-02-22 | Owens Corning Fiberglass Corp | Fibrous structures containing glass fibers and other fibers |
US3418203A (en) * | 1965-09-07 | 1968-12-24 | Owens Illinois Inc | Process of forming water-laid products of cellulosic fibers and glass fiber containing ligno-sulfonic acid and sodium silicate and products thereof |
US3773513A (en) * | 1969-09-12 | 1973-11-20 | Xerox Corp | Dimensionally stable photographic paper containing glass fibers |
US3844337A (en) * | 1972-12-18 | 1974-10-29 | Packaging Corp America | Pouring sprue |
US4081168A (en) * | 1974-09-12 | 1978-03-28 | Foseco Trading, A.G. | Hot top lining slabs and sleeves |
US4069859A (en) * | 1975-03-03 | 1978-01-24 | Sato Technical Research Laboratory Ltd. | Direct pouring method using self-fluxing heat-resistant sheets |
SE401918B (en) * | 1976-01-19 | 1978-06-05 | Rockwool Ab | WAY TO MANUFACTURE A MINERAL FIBER PRODUCT |
DE2941644C2 (en) * | 1978-10-17 | 1982-11-11 | Matsushita Electric Industrial Co., Ltd., Kadoma, Osaka | Loudspeaker cone and process for their manufacture |
AU526880B2 (en) * | 1978-12-27 | 1983-02-03 | Dyson Refractories Ltd. | Runners etc for bottom pouring |
FR2553121B1 (en) * | 1983-10-06 | 1986-02-21 | Arjomari Prioux | PAPER SHEET, ITS PREPARATION METHOD AND ITS APPLICATIONS, IN PARTICULAR AS A SUBSTITUTION PRODUCT FOR IMPREGNATED GLASS VEILS |
CN86100068B (en) * | 1986-01-07 | 1988-12-28 | 孙孟全 | Spherical heatproof riser cover |
DE3725248A1 (en) * | 1987-07-30 | 1989-02-09 | Henkel Kgaa | ANTIMICROBIAL EFFICIENT, FLAVORED PREPARATIONS |
US5205340A (en) * | 1989-06-27 | 1993-04-27 | Brown Foundry System, Inc. | Insulated paper sleeve for casting metal articles in sand molds |
US4981166A (en) * | 1989-06-27 | 1991-01-01 | Brown Foundry Systems, Inc. | Foundry paper riser and system therefor |
CN1017030B (en) * | 1990-07-24 | 1992-06-17 | 鸡西市柳毛石墨矿 | Solid coating for steel ingot mold and its production method |
US5830548A (en) * | 1992-08-11 | 1998-11-03 | E. Khashoggi Industries, Llc | Articles of manufacture and methods for manufacturing laminate structures including inorganically filled sheets |
US5242006A (en) * | 1992-10-14 | 1993-09-07 | Eudelio Ortega | Drapery weight and method |
DK169925B1 (en) * | 1993-02-23 | 1995-04-03 | Dacompa As | Method and plant for producing molded blank and molded blank |
CN1037589C (en) * | 1993-06-19 | 1998-03-04 | 包钢耐火材料厂 | Light heat-insulating shield for cast ingot |
JP3139918B2 (en) * | 1993-12-28 | 2001-03-05 | 株式会社キャディック・テクノロジ−・サ−ビス | Method for producing refractory molded article and binder for refractory molded article |
US5766686A (en) * | 1996-03-01 | 1998-06-16 | North American Refractories Co. | Spray insulating coating for refractory articles |
JPH09253792A (en) * | 1996-03-25 | 1997-09-30 | Nissan Motor Co Ltd | Paper core for casting and its manufacture |
US5806712A (en) * | 1996-10-30 | 1998-09-15 | Crane Co. | Vending machine for dispensing beverage containers |
ATE240433T1 (en) * | 1997-03-31 | 2003-05-15 | Fibermark Inc | METHOD FOR PRODUCING A WET-LAID WEB FROM METAL FIBERS AND METAL POWDER |
WO1998044198A1 (en) * | 1997-03-31 | 1998-10-08 | Fibermark Inc. | Method of making a metal fiber sheet |
EP0986429A4 (en) * | 1997-06-02 | 2001-02-07 | Hitco Carbon Composites Inc | High performance filters |
US6278448B1 (en) * | 1998-02-17 | 2001-08-21 | Microsoft Corporation | Composite Web page built from any web content |
EP1081285B1 (en) * | 1998-02-23 | 2008-06-04 | Kao Corporation | Method of manufacturing pulp mold formed product |
WO1999042659A1 (en) * | 1998-02-23 | 1999-08-26 | Kao Corporation | Method of manufacturing pulp molded product |
JP3962146B2 (en) * | 1998-03-03 | 2007-08-22 | Nskワーナー株式会社 | Wet friction material and manufacturing method thereof |
US5989390A (en) * | 1999-01-06 | 1999-11-23 | Knowlton Specialty Papers, Inc. | Friction paper containing activated carbon |
EP1195466B1 (en) * | 1999-01-29 | 2011-04-06 | Kao Corporation | Method of manufacturing pulp mold formed body and apparatus thereof |
GB0004681D0 (en) * | 2000-02-28 | 2000-04-19 | Saffil Limited | Method of making fibre-based products and their use |
US7077933B2 (en) * | 2000-03-01 | 2006-07-18 | Kao Corporation | Pulp molded body |
EP1285994A4 (en) * | 2000-04-11 | 2007-12-12 | Kao Corp | Method of producing pulp moldings |
US6918997B2 (en) * | 2000-04-18 | 2005-07-19 | Kao Corporation | Method of producing pulp moldings |
US20020096278A1 (en) * | 2000-05-24 | 2002-07-25 | Armstrong World Industries, Inc. | Durable acoustical panel and method of making the same |
EP1186704A1 (en) * | 2000-09-08 | 2002-03-13 | Ruey Ling Chen | Asphalt-grade carbon fiber paper and process for making the same |
JP2002207612A (en) * | 2001-01-12 | 2002-07-26 | Hitachi Ltd | Log analyzing method and its execution device, and recording medium with recorded processing program thereof |
US6533897B2 (en) * | 2001-04-13 | 2003-03-18 | Fmj Technologies, Llc | Thermally and structurally stable noncombustible paper |
US6488811B1 (en) * | 2001-04-30 | 2002-12-03 | Owens Corning Fiberglas Technology, Inc. | Multicomponent mats of glass fibers and natural fibers and their method of manufacture |
JP3415607B2 (en) * | 2001-07-24 | 2003-06-09 | 花王株式会社 | Method for producing fiber molded body |
EP1413676A4 (en) * | 2001-07-31 | 2007-11-14 | Kao Corp | Method of manufacturing hollow fiber formed body, hollow fiber formed body, and device for manufacturing the hollow fiber formed body |
US20040045690A1 (en) * | 2001-08-03 | 2004-03-11 | Keiji Eto | Molded pulp product, and method and apparatus for production thereof |
JP4002200B2 (en) * | 2002-03-13 | 2007-10-31 | 花王株式会社 | Papermaking parts for casting production |
US6616802B1 (en) * | 2002-04-10 | 2003-09-09 | Fibermark, Inc. | Process and apparatus for making a sheet of refractory fibers using a foamed medium |
JP4471629B2 (en) * | 2002-11-13 | 2010-06-02 | 花王株式会社 | Manufacturing method of parts for casting production |
JP3995649B2 (en) * | 2002-11-29 | 2007-10-24 | 花王株式会社 | Molds or structures for casting production |
KR100998461B1 (en) * | 2002-12-09 | 2010-12-06 | 카오카부시키가이샤 | Spherical casting sand |
JP4154727B2 (en) * | 2003-04-22 | 2008-09-24 | 王子製紙株式会社 | Wet method nonwoven fabric and method for producing the same |
JP4439315B2 (en) * | 2004-03-31 | 2010-03-24 | 花王株式会社 | Manufacturing method of papermaking molded body |
CN1942262B (en) * | 2004-06-10 | 2010-12-01 | 花王株式会社 | Structure for casting production, casting manufacture method and uses |
JP4601531B2 (en) * | 2004-10-12 | 2010-12-22 | 花王株式会社 | MANUFACTURING METHOD AND DEVICE FOR FIBER MOLDED ARTICLE, FIBER MOLDING INTERMEDIATE AND FIBER MOLDED |
US9802866B2 (en) * | 2005-06-09 | 2017-10-31 | United States Gypsum Company | Light weight gypsum board |
US20070039703A1 (en) * | 2005-08-19 | 2007-02-22 | Lee Jerry H | Wet formed mat having improved hot wet tensile strengths |
US20080135721A1 (en) * | 2006-12-06 | 2008-06-12 | General Electric Company | Casting compositions for manufacturing metal casting and methods of manufacturing thereof |
-
2006
- 2006-11-29 CN CN2006800440683A patent/CN101316665B/en not_active Expired - Fee Related
- 2006-11-29 EP EP06833601.5A patent/EP1958717B1/en not_active Expired - Fee Related
- 2006-11-29 US US12/085,686 patent/US20090211717A1/en not_active Abandoned
- 2006-11-29 WO PCT/JP2006/323797 patent/WO2007063888A1/en active Application Filing
- 2006-11-29 KR KR1020087012875A patent/KR101205749B1/en active IP Right Grant
Non-Patent Citations (1)
Title |
---|
None * |
Also Published As
Publication number | Publication date |
---|---|
KR101205749B1 (en) | 2012-11-28 |
EP1958717A4 (en) | 2011-04-13 |
CN101316665A (en) | 2008-12-03 |
EP1958717A1 (en) | 2008-08-20 |
WO2007063888A1 (en) | 2007-06-07 |
US20090211717A1 (en) | 2009-08-27 |
KR20080072013A (en) | 2008-08-05 |
CN101316665B (en) | 2011-04-27 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP1958717B1 (en) | Component for casting production and method for producing same | |
JP5036762B2 (en) | Casting parts | |
EP1757383B1 (en) | Molded body | |
JP6682159B2 (en) | Method for manufacturing structure for casting production | |
US7503999B2 (en) | Member for producing castings | |
JP4749138B2 (en) | Tubular casting parts | |
JP2007175771A (en) | Component for manufacturing cast product, and its manufacturing method | |
JP4869786B2 (en) | Casting structure | |
JP4672522B2 (en) | Casting structure | |
JP5057756B2 (en) | Casting production parts and method for producing the same | |
JP4980811B2 (en) | Mold and composite mold | |
JP7078789B2 (en) | Structure for manufacturing castings | |
JP4757002B2 (en) | Papermaking compacts used in connecting structures for fluid transport pipes | |
JP4072984B2 (en) | Preform for metal matrix composite and method for producing the same | |
JP3351599B2 (en) | Foam board | |
JP2003113598A (en) | Base paper for honeycomb core and honeycomb core | |
RU2394793C2 (en) | Article made from fire-resistant, composite layered material |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
17P | Request for examination filed |
Effective date: 20080604 |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): DE FR GB |
|
DAX | Request for extension of the european patent (deleted) | ||
RBV | Designated contracting states (corrected) |
Designated state(s): DE FR GB |
|
A4 | Supplementary search report drawn up and despatched |
Effective date: 20110314 |
|
17Q | First examination report despatched |
Effective date: 20160629 |
|
GRAP | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOSNIGR1 |
|
INTG | Intention to grant announced |
Effective date: 20181004 |
|
GRAS | Grant fee paid |
Free format text: ORIGINAL CODE: EPIDOSNIGR3 |
|
GRAA | (expected) grant |
Free format text: ORIGINAL CODE: 0009210 |
|
AK | Designated contracting states |
Kind code of ref document: B1 Designated state(s): DE FR GB |
|
REG | Reference to a national code |
Ref country code: GB Ref legal event code: FG4D |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R096 Ref document number: 602006057288 Country of ref document: DE |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R097 Ref document number: 602006057288 Country of ref document: DE |
|
PLBE | No opposition filed within time limit |
Free format text: ORIGINAL CODE: 0009261 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT |
|
26N | No opposition filed |
Effective date: 20191010 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: DE Payment date: 20201118 Year of fee payment: 15 Ref country code: GB Payment date: 20201118 Year of fee payment: 15 Ref country code: FR Payment date: 20201013 Year of fee payment: 15 |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R119 Ref document number: 602006057288 Country of ref document: DE |
|
GBPC | Gb: european patent ceased through non-payment of renewal fee |
Effective date: 20211129 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: GB Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20211129 Ref country code: DE Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20220601 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: FR Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20211130 |