JP2009531271A - Manufacture of ceramic molds - Google Patents

Manufacture of ceramic molds Download PDF

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Publication number
JP2009531271A
JP2009531271A JP2009502977A JP2009502977A JP2009531271A JP 2009531271 A JP2009531271 A JP 2009531271A JP 2009502977 A JP2009502977 A JP 2009502977A JP 2009502977 A JP2009502977 A JP 2009502977A JP 2009531271 A JP2009531271 A JP 2009531271A
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Prior art keywords
matrix
slurry
ceramic
mold
cloth
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スミス，デイビッド
パッティロー，ポール
ホーグランド，ピーター
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ベスビウス クルーシブル カンパニー
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0022—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors
    • C04B38/0032—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors one of the precursor materials being a monolithic element having approximately the same dimensions as the final article, e.g. a paper sheet which after carbonisation will react with silicon to form a porous silicon carbide porous body
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00939—Uses not provided for elsewhere in C04B2111/00 for the fabrication of moulds or cores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Abstract

本発明はセラミック成形型を形成する方法に関する。前記方法は、セラミッククロスをスラリーに含浸する工程；母型の周りに前記クロスを巻く工程；および前記スラリーを硬化させる工程を含む。前記方法は、母型を除去する工程をさらに含む。  The present invention relates to a method of forming a ceramic mold. The method includes impregnating a ceramic cloth with a slurry; wrapping the cloth around a matrix; and curing the slurry. The method further includes removing the matrix.

Description

本発明は、耐火性形材(refractory shapes)の形成に利用される母型(forms)または成形型(molds)の製造に関する。   The present invention relates to the manufacture of molds or molds used to form refractory shapes.

金属産業において、溶融金属は耐火性物品の中を流れ、または耐火性物品により運搬される。インダクター、レードルおよび他の導管などの物品は耐火性材料から構成されている。   In the metal industry, molten metal flows through or is carried by refractory articles. Articles such as inductors, ladles and other conduits are constructed from refractory materials.

種々の耐火性形材は、当分野に公知のとおり成形型または母型を利用して形成される。母型は典型的には紙、木または金属などの材料から構成されている。耐火性材料は母型の周囲に置かれ、所望の形状にさせる。次いで、母型材料は、耐火性材料でなく高熱に耐えられないので、加熱中にまたは耐火性材料に熱が加わる前のいずれかに、ライニング（耐火性材料）から除去しなくてはならない。多くの用途において、不規則な形状または他の制約のため、成形型を除去することが非常に困難である。成形型を永久にそのまま残すことが可能ならば問題はなくなる。   The various refractory profiles are formed using a mold or matrix as is known in the art. The matrix is typically composed of a material such as paper, wood or metal. The refractory material is placed around the matrix and allowed to have the desired shape. The matrix material is then not a refractory material and cannot withstand high heat, so it must be removed from the lining (refractory material) either during heating or before heat is applied to the refractory material. In many applications, it is very difficult to remove the mold due to irregular shapes or other constraints. There is no problem if the mold can be left as it is.

溶融亜鉛または溶融アルミニウムの処理などの特定の用途において、現在使用されている耐火性材料は亀裂を形成しやすい。これらの耐火性材料の作用表面の不撓性により亀裂の形成および伝播が起こる。   In certain applications, such as the treatment of molten zinc or molten aluminum, currently used refractory materials are prone to cracking. The inflexibility of the working surface of these refractory materials causes crack formation and propagation.

提案されている解決法の１つは、スリップキャスティング技術によりセラミック成形型を製造することである。しかし、これらは脆く、製造が困難である。   One proposed solution is to produce ceramic molds by slip casting technology. However, they are fragile and difficult to manufacture.

母型または成形型が、耐火性形材の使用温度で機能できる材料から形成されていれば有益であろう。   It would be beneficial if the matrix or mold was formed from a material that could function at the operating temperature of the refractory profile.

本発明はセラミック成形型を製造する方法に関する。前記方法は、セラミッククロスにスラリーを含浸する工程、母型の周りを前記クロスで包むまたは前記クロスを母型の上に置く工程およびスラリーを硬化させる工程を含む。前記方法は母型を除去する工程をさらに含む。しかし、特定の形状において、低温成形要素を、その存在がセラミック成形型の使用に有害にならない場合、そのまま残すことができる。   The present invention relates to a method of manufacturing a ceramic mold. The method includes impregnating a ceramic cloth with the slurry, wrapping the matrix around the matrix with the cloth or placing the cloth on the matrix, and curing the slurry. The method further includes removing the matrix. However, in certain shapes, the low temperature forming element can be left intact if its presence is not detrimental to the use of the ceramic mold.

本発明の実施形態によると、セラミック成形型を形成する方法は、セラミッククロスにスラリーを含浸する工程を含む。織布の織りの隙間により、含浸が可能になる。本発明の１実施形態において、セラミッククロスは、幅が約１インチから約２インチのセラミッククロステープである。この幅はテープのより容易な取扱いを可能にする。ただし、セラミッククロステープは、許容できる幅であれば用いることができる。クロステープをスラリー中に浸すことにより、クロステープにスラリーが含浸される。含浸は、大気圧でも、真空、圧力を利用しても、真空と圧力の組み合わせを利用してスラリーをクロス中に押し入れても実施できる。セラミッククロスは、例えば、シリカまたは酸化クロムを含んでいてよい。   According to an embodiment of the present invention, a method of forming a ceramic mold includes impregnating a ceramic cloth with a slurry. Impregnation is possible due to the interstices of the woven fabric. In one embodiment of the present invention, the ceramic cloth is a ceramic cloth tape having a width of about 1 inch to about 2 inches. This width allows for easier handling of the tape. However, the ceramic cloth tape can be used if it has an allowable width. The cloth tape is impregnated with the slurry by immersing the cloth tape in the slurry. Impregnation can be carried out at atmospheric pressure, using vacuum, pressure, or pushing the slurry into the cloth using a combination of vacuum and pressure. The ceramic cloth may contain, for example, silica or chromium oxide.

スラリーは、乾燥時に硬化し且つ耐火性物品の使用に伴う温度に耐える好適な材料を含む。好ましくは、セメント結合スラリーが使用されるが、どのような好適な結合システムも使用できる。１実施形態において、スラリーは、シリカ繊維強化されたアルミナ−クロムスラリーである。   The slurry comprises a suitable material that cures upon drying and withstands the temperatures associated with the use of refractory articles. Preferably, cement bonded slurry is used, but any suitable bonding system can be used. In one embodiment, the slurry is a silica fiber reinforced alumina-chromium slurry.

本発明のスラリーの構成要素は、酸化アルミニウム、二酸化ケイ素および二酸化チタンを含むことがある耐火性カルサイン（ＭＵＬＣＯＡ ６０など）；焼成アルミナ；セメント；ボールクレーまたは他のモンモリロナイト含有粘土などの粘土（Ｍ＆Ｄクレーなど）；微粒シリカ；解膠剤（ホスフェート解膠剤ＢＵＤＩＰＵＲ ８Ｈなど）；コロイダルシリカ；酸化クロム；カヤナイト；水；シリカ繊維；炭化ケイ素；炭素；ジルコン；ジルコニア；マグネシウム；および他の金属を含む。   The components of the slurry of the present invention include refractory calcine (such as MULCOA 60) that may include aluminum oxide, silicon dioxide and titanium dioxide; calcined alumina; cement; clay such as ball clay or other montmorillonite-containing clay (M & D clay) Fine particle silica; peptizer (such as phosphate peptizer BUDIPUR 8H); colloidal silica; chromium oxide; kayanite; water; silica fiber; silicon carbide; carbon;

セラミッククロステープにスラリーを含浸して、母型の周りを包み、または母型の上に置き、成形して適切な幾何学形状を生みだすか、または、得られる耐火性物品中に適切な表面を形成する。母型は、母型の燃焼などにより、耐火性物品の製造後に除去できる材料でできていてよい。１実施形態において母型はポリスチレンフォームでできているが、他の好適な材料も使用できる。   Impregnate the ceramic cloth tape with the slurry and wrap around the matrix or place it on the matrix and mold it to produce the appropriate geometry or place the appropriate surface in the resulting refractory article Form. The matrix may be made of a material that can be removed after the refractory article is manufactured, such as by burning the matrix. In one embodiment, the matrix is made of polystyrene foam, but other suitable materials can be used.

スラリーを含浸したテープを母型の上または周りに置いた後、セラミッククロステープを乾燥する。乾燥すると、高温に耐え、亀裂に耐え、腐食に耐える繊維強化セラミックの可撓性複合マトリックスを形成する。この可撓性のために、本発明の製造物が、亜鉛およびアルミニウムなどの溶融金属の処理において作用表面に使用される場合に、亀裂形成に対するバリアとして作用することができる。   After the tape impregnated with the slurry is placed on or around the matrix, the ceramic cloth tape is dried. Upon drying, it forms a flexible composite matrix of fiber reinforced ceramic that resists high temperatures, resists cracking, and resists corrosion. Because of this flexibility, the product of the present invention can act as a barrier to crack formation when used on the working surface in the treatment of molten metals such as zinc and aluminum.

セラミッククロステープが乾燥したら、母型をセラミック成形型から除去してよい。ポリスチレンフォーム母型を利用する実施形態において、母型が成形型から焼け落ちるまでセラミック成形型および母型を加熱することにより、母型を除去してよい。次いで、灰は従来の手段により除去できる。適切な母型材料に化学溶剤を使用して、母型を除去してもよい。   Once the ceramic cloth tape is dry, the matrix may be removed from the ceramic mold. In embodiments utilizing a polystyrene foam mother mold, the mother mold may be removed by heating the ceramic mold and the mother mold until the mother mold burns off the mold. The ash can then be removed by conventional means. A matrix may be removed using a chemical solvent in a suitable matrix material.

本発明の形態的な実施形態において、母型は平坦な表面でもよく、そのため製造される成形型は平坦な表面を有するパネルを構成する。   In a morphological embodiment of the present invention, the matrix may be a flat surface, so that the mold that is produced constitutes a panel having a flat surface.

以下の組成を有する、サンプルスラリーを作った：
ＭＵＬＣＯＡ ６０−２００Ａ １８．９８％
焼成アルミナ ６．３３％
セメント ８．８６％
Ｍ＆Ｄクレー ０．７９％
エルケムマイクロシリカ ３．１６％
ＢＵＤＩＰＵＲ ８Ｈ ０．１６％
コロイダルシリカ ４．７４％
酸化クロム ３．１６％
−１００ｍ カヤナイト １２．６５％
水 ６．１７％
シリカ繊維 ３５．００％
レフラシルテープをスラリーに浸し、ポリスチレンフォーム母型に巻き付けた。母型はインダクターループ用に成形されていた。スラリーを風乾した。最後に、耐火性材料を母型の周りに詰め、材料を予備加熱し、ポリスチレンフォーム母型を焼き尽くした。酸化クロムなしで上述の比率どおりにスラリーを作ることもできる。 A sample slurry was made having the following composition:
MULCOA 60-200A 18.98%
Firing alumina 6.33%
Cement 8.86%
M & D clay 0.79%
Elchem Microsilica 3.16%
BUDIPUR 8H 0.16%
Colloidal silica 4.74%
Chromium oxide 3.16%
-100m Kayanite 12.65%
Water 6.17%
Silica fiber 35.00%
The lefrasil tape was immersed in the slurry and wound around a polystyrene foam matrix. The master was molded for the inductor loop. The slurry was air dried. Finally, a refractory material was packed around the matrix, the material was preheated, and the polystyrene foam matrix was burned out. Slurries can also be made without the chromium oxide as described above.

明らかに、本発明の多くの修正および変更が可能である。したがって、以下の特許請求項の範囲内で、具体的に記載したのとは別な方法で本発明を実施可能であることを理解されたい。本発明を特定の実施形態に関して説明したが、本発明への種々の変更、修正および追加が当業者には明らかであろう。そのような修正、変更および追加は本発明の範囲に含包されるものであり、本発明は本願に添付する特許請求項にのみ限定される。   Obviously, many modifications and variations of the present invention are possible. It is therefore to be understood that within the scope of the following claims, the invention may be practiced otherwise than as specifically described. Although the invention has been described with reference to particular embodiments, various changes, modifications and additions to the invention will be apparent to those skilled in the art. Such modifications, changes and additions are intended to be included within the scope of the invention, which is limited only by the claims appended hereto.

Claims (14)

セラミッククロスにスラリーを含浸する工程、母型の周りに前記クロスを巻く工程、および前記スラリーを硬化させる工程を含む、セラミック成形型を形成する方法。   A method of forming a ceramic mold, the method comprising impregnating a ceramic cloth with a slurry, winding the cloth around a matrix, and curing the slurry. 前記母型を成形型から除去する工程をさらに含む、請求項１に記載の方法。   The method of claim 1, further comprising removing the matrix from the mold. 前記スラリーがセメントを含む、請求項１に記載の方法。   The method of claim 1, wherein the slurry comprises cement. 前記スラリーがアルミナを含む、請求項１に記載の方法。   The method of claim 1, wherein the slurry comprises alumina. 前記スラリーが酸化クロムを含む、請求項１に記載の方法。   The method of claim 1, wherein the slurry comprises chromium oxide. 前記スラリーがシリカ繊維を含む、請求項１に記載の方法。   The method of claim 1, wherein the slurry comprises silica fibers. 前記母型がポリスチレンフォームを含む、請求項１に記載の方法。   The method of claim 1, wherein the matrix comprises polystyrene foam. 前記母型が加熱により成形型から除去される、請求項１に記載の方法。   The method of claim 1, wherein the matrix is removed from the mold by heating. 前記スラリーが、耐火性カルサイン、セメント、粘土、微粒シリカ、解膠剤、コロイダルシリカ、酸化クロム、カヤナイト、水およびシリカ繊維を含む、請求項１に記載の方法。   The method of claim 1, wherein the slurry comprises refractory calcine, cement, clay, fine silica, peptizer, colloidal silica, chromium oxide, kayanite, water and silica fibers. 前記セラミッククロスがシリカを含む、請求項１に記載の方法。   The method of claim 1, wherein the ceramic cloth comprises silica. 前記セラミッククロスが酸化クロムを含む、請求項１に記載の方法。   The method of claim 1, wherein the ceramic cloth comprises chromium oxide. セラミッククロスにスラリーを含浸する工程、母型の上に前記クロスを置く工程、および前記スラリーを硬化させる工程を含む、セラミック成形型を形成する方法。   A method of forming a ceramic mold, comprising impregnating a ceramic cloth with a slurry, placing the cloth on a matrix, and curing the slurry. 前記母型を成形型から除去する工程をさらに含む、請求項１２に記載の方法。   The method of claim 12, further comprising removing the matrix from the mold. 前記母型が平坦な表面を持つパネルを含む、請求項１２に記載の方法。   The method of claim 12, wherein the matrix includes a panel having a flat surface.
JP2009502977A 2006-03-28 2007-03-27 Manufacture of ceramic molds Pending JP2009531271A (en)

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US78666706P 2006-03-28 2006-03-28
PCT/US2007/007689 WO2007126895A1 (en) 2006-03-28 2007-03-27 Manufacture of ceramic molds

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AR (1) AR060146A1 (en)
EA (1) EA013188B1 (en)
TW (1) TW200740579A (en)
WO (1) WO2007126895A1 (en)
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