JP6684418B2 - 鋳型の製造方法 - Google Patents
鋳型の製造方法 Download PDFInfo
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- JP6684418B2 JP6684418B2 JP2015243177A JP2015243177A JP6684418B2 JP 6684418 B2 JP6684418 B2 JP 6684418B2 JP 2015243177 A JP2015243177 A JP 2015243177A JP 2015243177 A JP2015243177 A JP 2015243177A JP 6684418 B2 JP6684418 B2 JP 6684418B2
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- binder
- mold
- phenol resin
- coated refractory
- coating layer
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- VKYKSIONXSXAKP-UHFFFAOYSA-N hexamethylenetetramine Chemical compound C1N(C2)CN3CN1CN2C3 VKYKSIONXSXAKP-UHFFFAOYSA-N 0.000 claims description 52
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- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 21
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- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
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- HQABUPZFAYXKJW-UHFFFAOYSA-N butan-1-amine Chemical compound CCCCN HQABUPZFAYXKJW-UHFFFAOYSA-N 0.000 description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 2
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- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical group [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 1
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Description
とによって、成形型内で水蒸気から凝縮水が過剰に生成されることが少なくなり、型内の粘結剤コーテッド耐火物の温度上昇の速度を速めることができるものである。
攪拌機と還流冷却器を備えた5リットルの四ツ口フラスコに、フェノールを1000g、37質量%ホルマリンを1383g、酢酸亜鉛を2.0g仕込み、混合攪拌しつつ約60分を要して還流させ、そのまま30分間反応させた。次いで内温が140℃になるまで常圧で脱液を行ない、さらに0.0133MPaの減圧下で100℃まで脱液を行なった。その後、フラスコの内容物をステンレス製バットの上に払い出し、室温にまで冷却することによって、固形のジメチレンエーテル型フェノール樹脂Aを得た。
四ツ口フラスコへの仕込みを、フェノールを700g、ビスフェノールAを300g、37質量%ホルマリンを1026g、酢酸亜鉛を1.4gに変更するするようにした他は、上記の(ジメチレンエーテル型フェノール樹脂の調製例A)と同様にして、固形のジメチレンエーテル型フェノール樹脂Bを得た。
還流冷却器を備えた5リットルの四ツ口フラスコに、フェノールを1880g、37質量%ホルマリンを1297g、シュウ酸(二水和物)を7.36g仕込み、約60分を要して還流させ、そのまま120分間反応させた。次いで内温が180℃になるまで常圧で脱液を行ない、さらに0.0093MPaの減圧下で200℃まで脱液を行なった。その後、フラスコの内容物をステンレス製バットの上に払い出し、室温にまで冷却することによって、固形のノボラック型フェノール樹脂Cを得た。
2リットルの四ツ口フラスコに、フェノールを680g、37質量%ホルマリンを680g、ヘキサメチレンテトラミンを101g仕込み、約60分を要して70℃まで昇温させ、そのまま5時間反応させた。そして0.0133MPaの減圧下で90℃まで減圧脱水を行なった後、フラスコの内容物をステンレス製バットの上に払い出し、室温にまで冷却することによって、固形のアンモニアレゾール型フェノール樹脂Dを得た。
135℃に加熱したフラタリーけい砂30kgをワールミキサーに仕込み、これに表2に示す固形のフェノール樹脂A〜Dを、フェノール樹脂が合計で750gとなるように加え、30秒間混錬した後、必要に応じて、ヘキサメチレンテトラミン、サリチル酸(ジメチレンエーテル型フェノール樹脂の硬化促進剤)を450gの水に溶解乃至分散させたものを添加し、砂粒の塊が崩壊するまで混錬した。次いで、さらに滑剤としてステアリン酸カルシウム30gを加えて30秒間混練し、これをワールミキサーから払い出してエアレーションを行なって冷却することによって、けい砂に対するフェノール樹脂の被覆量が2.5質量%のコーティング層で表面が被覆された粘結剤コーテッド耐火物を得た。このようにして得た粘結剤コーテッド耐火物は、表面のコーティング層は固形であって、さらさらとした流動性の良好な粒子であった。尚、表2にはフラタリーけい砂の質量を100部としたときの質量部で配合量を示す。
キャビティの大きさが30cm×10cm×4cmに形成された成形金型を250℃に加熱して用いた。そして表3のように粘結剤コーテッド耐火物として実施例2,5,10、比較例1,2のものを用い、成形金型にゲージ圧力0.1MPaの空気圧で吹き込んで充填した。そして表3に示す時間保持して、粘結剤コーテッド耐火物を成形金型内で加熱して鋳型を製造した。
2 粘結剤コーテッド耐火物
Claims (12)
- 上記コーティング層には、ノボラック型フェノール樹脂が含有されていることを特徴とする請求項1に記載の鋳型の製造方法。
- コーティング層に含有されるジメチレンエーテル型フェノール樹脂とノボラック型フェノール樹脂の質量比率は、90:10〜5:95の範囲であることを特徴とする請求項2に記載の鋳型の製造方法。
- 上記コーティング層には、ホルムアルデヒドと反応する窒素含有化合物が含有されていることを特徴とする請求項1乃至3のいずれかに記載の鋳型の製造方法。
- 上記窒素含有化合物は、へキサメチレンテトラミン、メラミン、尿素から選ばれるものであることを特徴とする請求項4に記載の鋳型の製造方法。
- 上記コーティング層には、ジメチレンエーテル型フェノール樹脂の硬化促進剤として酸が含有されていることを特徴とする請求項1乃至5のいずれかに記載の鋳型の製造方法。
- 上記コーティング層には、炭素質材料が含有されていることを特徴とする請求項1乃至6のいずれかに記載の鋳型の製造方法。
- 成形型内に水蒸気を通した後、次いで加熱した気体を成形型内に通すことを特徴とする請求項1乃至7のいずれかに記載の鋳型の製造方法。
- 上記の加熱した気体が、加熱した空気であることを特徴とする請求項8に記載の鋳型の製造方法。
- 上記の加熱した気体が、水蒸気と空気の混合気体であることを特徴とする請求項8に記載の鋳型の製造方法。
- 上記の水蒸気が、過熱水蒸気であることを特徴とする請求項1乃至10のいずれかに記載の鋳型の製造方法。
- 予備加熱した粘結剤コーテッド耐火物を成形型に供給することを特徴とする請求項1乃至11のいずれかに記載の鋳型の製造方法。
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