WO2001090028A1

WO2001090028A1 - Moulding of ceramic moulding forms

Info

Publication number: WO2001090028A1
Application number: PCT/NO2001/000219
Authority: WO
Inventors: Gard Antonsen; Pål Francis HANSEN
Original assignee: Hiform As
Priority date: 2000-05-26
Filing date: 2001-05-25
Publication date: 2001-11-29
Also published as: AU2001262810A1; NO20002742L; NO20002742D0

Abstract

A method for making a ceramic moulding form (14'), e.g. for moulding or forming of composite materials, glasses or metals, comprising the following steps: force-mixing of a batch of ceramic powder (1) in the dry phase in a mixer (5) for even distribution of the powder components, to form a dry basis for a moulding mass (14); characterized by adding a water solution (2) containing a small amount of a water surface tension reducing agent (4) slowly into the powder (1) to form a batch of moulding mass (14) in the running force-mixer (5); adding reinforcing fibres (3) slowly and evenly into the batch of moulding mass (14) in the running force-mixer (5); transferring the batch of moulding mass (14) to a vacuum tob (7); extracting air by pumping vacuum in the vacuum tob (7)and transfering the vacuum tob (7) to a rolling bed (7c) for rotation for evacuation of entrapped air bubbles from the batch of moulding mass (14); and injecting the batch of moulding mass (14) into a mould form (11), leaving the moulding mass (14) to harden into a moulding form (14').

Description

MOULDING OF CERAMIC MOULDING FORMS.

The present invention relates to moulding of ceramic moulding forms, hereafter called moulds, for use in moulding of composite materials like reinforced thermoplastic, and for thermoforming and metal cast moulding.

The known art .

An existing product from Elkem, a dry powder cement containing ceramic additives, is called CSA, or similar cements containing ceramic additives, and are sold in bulk and prepared for mixing with water and used for moulding of ceramic devices for high-temperature use, e.g. for molten metal. Such powder cements have the property of very little volume change during solidification which may be due to low water volume loss and the wide grain size distribution giving a well filled-in packing structure. The ceramic moulds thus formed are very temperature resistant and have a good structural integrity. Ceramic moulds are traditionally used for making transfer channels and coguille forms for raw aluminium or other metal bar moulding. Plasma spraying is performed by mould formation by blowing a mixture of ceramic or metal powder through a flame nozzle, so-called plasma spraying, and thereby building up a ceramic or metallic layer of desired thickness against of a positive model of an object to be formed, and then removing the model, and is described in US-patents

Disadvantages of the known art.

Entrapped air bubbles in the mould material incurs an uneven moulding surface. Such a surface is not suitable composite production of finer surfaces like interior parts for cars, thermal forming of glass, resin transfer moulding of boat hulls, and composite production using vacuumforming of commingled yarn of thermoplastic and reinforcing fibres, among several products having fine-structure surface. Entrapped air bubbles also reduce the structural integrity of the mould, and gives an uneven temperature distribution of the mould and the layup during heating and cooling cycles.

One way of getting around the problem of entrapped air bubbles is mould formation by plasma spraying mentioned above, building up a ceramic or metallic layer of desired thickness against a plug (a positive model of an object to be formed) . However, often smooth surface structure of the plug or model may be neither thermally resistant to the hot plasma particles arriving at very high speeds from the flame nozzle, nor impact resistant due to the very high particle speeds.

One purpose of the invention is to make a thermally resistant mould having a desired even surface smoothnes or structure.

Another purpose of the invention is to make a thermally resistant mould being free of entrapped air, both internally and in the mould surface.

An additional purpose of the invention is to make moulds having a high wear and scratch resistance.

Another additional purpose is to make moulds having high thermal conductivity.

Another purpose of the invention is to make moulds which have a low thermal expansion coefficient .

Another purpose of the invention is to make a thermally resistant mould of improved surface smoothness and having a release layer.

Figure captions.

Fig. 1 illustrates the process according to the invention, from the mixing of basic materials, and further treatment of the mould material through various procedures. In Fig. 2 in the right part of the same sheet, injecting of the liquid mould material into a mould is illustrated.

Fig. 3 illustrates a section of a. part of a moulding form according to the invention, illustrating supporting bars, a surface coating, and various vacuum, heating and cooling arrangements.

Fig. 4 illustrates a two-sided form acording to the invention forming a closed cavity, used in pressurized rd tn JH tn CQ r β ^•0 0 β φ

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Detailed description of preferred embodiments of the invention.

PROCEDURE FOR MOULD MATERIAL PREPARATION.

Some or all of the following tools and materials are needed:

A vibrator bed 12 for a mould form 11 and its plug.

A vibration bed 9 for a filling-tob 8

Ceramic cement powder 1, preferrably of the trade name CSA, by Elkem, or a similar cement containing ceramic additives. An existing product from Elkem, a dry powder cement containing ceramic additives, is called CSA, or similar cements containing ceramic additives, and are sold in bulk and prepared for mixing with water and normally used for moulding of devices for high temperature use, e.g. for molten metal. Such powder cements have the property of very little volume change during solidification which may be due to low water volume loss and the wide grain size distribution giving a well filled-in packing structure. The ceramic moulds thus formed are very temperature resistant and have a good structural integrity.

Reinforcing fibres 3, preferably about 4-6%, and most preferably 5% of the ceramic powder mass.

Water 2, preferably less than 7% by weight. The exact amount of water added to the ceramic powder mass 1 to form a moulding mass 14 may be very critical in order to obtain a sufficient quality of the ceramic mould produced, both with respect to structural strength and surface smoothness . In a preferred embodiment of the invention, the amount of water is between 5% and 6% by weight, preferrably more or equal to 5.3%, and most preferrably between 5.7% and 5.8%.

A water surface tension reducing agent 4, preferrably a dishwashing detergent, to an amount of about 1 drop per

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90

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JJ rH ft Φ Xi CQ ε fd Φ > Φ rH rH ε CQ -rl fH > ti Φ fH rH td fH X! Φ o

CQ r-i β ft • > JJ CQ TS fH JJ 0 JJ rH r-i ti Φ Φ Φ Φ A ϊs Φ JJ Φ £ Φ β ft Φ X! X! M υ

O fi Φ o β H fi -H td Φ 0 00 (6 ti td -rl -H 0 XI fH Xi xi Φ -H 0 fH td Xi 0 Xi o φ xi -rl β fd Φ

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fi tn TJ S MH ti

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O td O X! . fH φ o td φ O O TJ -H 0 Φ in υ JJ fi H φ ft XI Xi JJ Φ CQ

Z -. iH td td > rd , ε fH ε ft o φ rH ro u & φ fd rd β ti Φ ft ^■H 01 M-l fd

JJ S S X φ S π υ ε td

H Φ o o rH T ft ε T o Λ o 0 X td CQ -H o φ J CJ U CQ a β Φ β X! A φ φ ε Φ S g fi ft Φ Φ φ fH EH JJ . ε JJ JJ fH CQ X X α. rd td 0 β β Φ φ fi JJ fd Xi -H β Xi fi Φ td td fH JJ 0 JJ fd jJ o φ Φ β

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JJ

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O fH fH β Φ o φ i 0 β φ 0 0 Φ Φ CQ fi Xi Φ fi JJ fi Φ 0 X! ti X! ft Φ β rd xi φ β φ

O fd MH CQ r-i υ O PJ MH -rl JJ MH MH JJ a -rl -H JJ Xi td cn fd CQ ε JJ ft J td ti Φ > Jj JJ -H ti JJ

repeated.

PROCEDURE FOR APPLICATION OF A PERMANENT MOULD RELEASE SURFACE .

A coating instruction for the mould release system follows. Some tools and raw materials required are listed below.

Heat-treated mould component 14'.

A pure solvent for degreasing.

Fluid xylan or other PTFE or PFA or similar coating Spray equipment

Oven (settings preferably at 80C, 130C and 280C) .

Cloth.

The prefabricated and heat-treated moulding form 14' is checked for dirt-spots and should be totally cleaned and degreased. The oven and mould are preheated, preferably to

80C for coating. The mould 14' is then taken to a flash-off temperature at 130C, and after the flash-off taken directly to curing temperature of 280C. The mould 14' is preheated to coating temperature. The Xylan or other PTFE or PFA or similar has to be well shear mixed and pored into the spray- cup. Application to specified thickness onto mould (max. 80m) in one layer, resulting in almost full colour coverage. Inspect for satisfactory coverage of the release coating before proceeding. The mould 14' is heated to 130C with a temperature hold of 5 - 10 minutes, and then taken to cure temperature of 280C for 15 minutes. Cool the mould 14' slowly until approx. 100C and inspect release coating for failures.

Repair: Repairing possibilities of the permanent release system are limited, but possible. Scrape away the coating on the damaged area. Grain down with very fine paper (1500) the boundary area of the defect, obtaining an even crossover. Clean the area well for debris and dust, degrease and perform the steps as indicated above. Avoid keeping the mould at cure temperature for longer time than strictly needed .

Description of preferred embodiments.

Fig. 3 illustrates a moulding form 14' produced according to the embodiment for moulding or forming of composite materials, glasses or metals, made by force-mixing of a batch of ceramic powder 1 and water 2, by vacuumizing the batch of moulding mass 14 in a vacuum tob 7 before injecting the batch of moulding mass 14 into a mould form 11, leaving the moulding mass 14 to harden to a rigid mould 14'; and removing the mould from the mould form 11.

A moulding form produced according to the invention is characterized in that a solving a small amount of a water surface tension reducing agent 4 was added to the water 2 for preparing a water solution 2. Then reinforcing fibres 3 have been added into the mixer 5 during preparation of the batch of moulding mass 14, before transfering the vacuum tob 7 to a rolling bed 7c for rotation for evacuation of entrapped air bubbles from the batch of moulding mass 14 before injection into the mould form. In one possible embodiment of the invention, the mould form 11 is set under vacuum at least before and preferrably during transfer of the moulding mass 14 from the tob 7.

As shown in fig 3, internal mould channels 16 formed from pipes or wax lines (to be melted out) may be integrated in the cavity of the moulding form 11 before filling with the moulding mass 14. These channels 16 may be used for heating or cooling fluids. For heating, both for hardening of the moulding mass 14 and later for ordinary production moulding, electrical heater circuits 17 may be arranged in the moulding form 11, in order to integrate in the moulding mass 14 before hardening. Internal mould reinforcement metal bars 18 and external support beams 19 may advantageously be arranged.

Fig. 4 illustrates production RTM injection of matrix into fiber reinforcement in the hardened form 14'.

A piston ejector 24 may be arranged for releasing and ejecting the moulded, hardened product, as illustrated in fig. 5, here metal moulding.

Fig. 6 illustrates press-moulding from a plate 31 of metal, thermoplastic, or armed composite material by using a positive shaped mould piston 26 formed in ceramite according to the invention, or made in silicon, tree, or metal arranged on a cylinder 25, against a negative (or oppositely) shaped form 14 formed according to the invention.

Fig. 7 illustrates thermoforming of e.g. a plate 28 of glass, plastic or similar heated by means of an infrared heating device 29 or equivalent, and formed by a piston 14' formed according to the invention. Vacuum channels 30 draw the plate 28 to the desired shape on the piston form 14'.

List of reference numerals:

1 ceramic mass (dry)

2 : water

3 : fibre 4: water surface tension reducing agent, additive

5 : force mixer

6: mixer outlet

7a: vacuum tob (illustrated during filling)

7b: vacuum tob (illustrated during rotation, vacuumized) 8: filler tob

9 : vibrating support for filler tob

8b, 10: injection pipe

11: mould forming tool (plug and/or mould form)

12: vibrating support for mould form. 13 : vacuum pump

14: mixed, prepared moulding mass, later to become:

14 ' :hardened mould

15: mould surface layer (release means, glazing, slip surface) 16: internal mould channels

17: electrical heater circuits

18 : internal mould reinforcement bars

19: mould support bars

20: internal channel for sensors in the form. 21: procuct cavity/room for injection materials

22: injection pump

23 : cavity for smelted metal

24: ejector for moulded, hardened product

25: press cylinder 26: mould piston (for e.g. silicon, wood, metal, ceramic mass)

27: retaining formwork for press form

28: plastic material or glass plate or other material with plastic properties like glass 29: infrared heating device

30: vacuum channels

Claims

C l a i m s

1. A method for making a ceramic moulding form (14'), e.g. for moulding or forming of composite materials, glasses or metals, comprising the following steps: force-mixing of a batch of ceramic powder (1) in the dry phase in a mixer (5) for even distribution of the powder components, to form a dry basis for a moulding mass (14) ; characterized by adding less than 7% by weight of water (2) into the powder (1) to form a batch of moulding mass (14) in the running force-mixer (5) ; adding reinforcing fibres (3) into the batch of moulding mass (14) in the running force-mixer (5) ; transferring the batch of moulding mass (14) to a vacuum tob (7) ; extracting air by pumping vacuum in the vacuum tob (7) and transfering the vacuum tob (7) to a rolling bed (7c) for rotation for evacuation of entrapped air bubbles from the batch of moulding mass (14) ; and injecting the batch of moulding mass (14) into a mould form (11) , leaving the moulding mass (14) to harden into a moulding form (14').

2. Method according to claim 1, the water (2) being a solution containing a small amount of a water surface tension reducing agent (4) .

3. Method according to claim 1, the amount of water (2) being more than 5% and less than 6%.

4. Method according to claim 1, the amount of water being between 5.7% and 5.8%.

5. Method according to claim 1, characterized by transferring the moulding mass (14) into a filling-tob (8) connected to the mould form (11) .

6. Method according to claim 5, characterized in that the filling-tob (8) is vibrated, preferrably by a vibration bed (9) during transfer of the moulding mass from the vacuum tob (7) to the mould form (11) .

. Method according to claim 1, characterized in that the mould form (11) is vibrated at least during the time from start of transfer of the moulding mass (14) into the mould form (11) , and until the mould form (11) is partially or completely filled.

S . Method according to claim 5, characterized in that a tob (7) containing a second or succeding batch of moulding mass (14), are inserted with the filling/pouring closure plunged into a previous batch (14) in the filler-tob (8) and opened under the surface of the preceeding batch (14) .

^} . Method according to claim 5, characterized in that the filler-tob (8) and the connected mould form (11) is set under vacuum before and during transfer of moulding mass (14) from the tob (7) in order to avoid entrapping of air or other gases in the moulding mass (14) .

[ . Method according to claim 1, characterized in leaving the moulding mass (14) to harden in the closed mould (11) for at least 24 hours, preferrably for at least 5 days.

,- Method according to claim 1 or 9, characterized in heating the formed moulding mass (14') slowly to allow entrapped water or water vapour to escape, and then heating the formed moulding mass (14') to approximately 300 degrees Celsius to cure.

12,. Method according to claim 10, characterized in heating the moulding mass (14') in steps.

IMS . Method according to claim 1, characterized by the following steps: cleaning and degreasing of the surface hard mould (14') ; heating the mould (14') to approximately 80 degrees Celsius; application of liquid xylan or other PTFE or PFA or similar to a desired thickness, preferrably max. 80mu, onto the mould (14) , to form a release layer or slip surface (15); heating the mould (14') with the release layer (15) to a flash-off temperature of approximately 130 degrees Celsius, and then to curing temperature of 280 degrees Celsius, and then cooling the mould slowly.

tst . A moulding form (14') for moulding or forming of composite materials, glasses or metals, made by the following steps : force-mixing of a batch of ceramic powder (1) and water (2) , characterized by vacuumizing the batch of moulding mass (14) in a vacuum tob (7) before injecting the batch of moulding mass (14) into a mould form (11) , leaving the moulding mass (14) to harden to a rigid moulding form (14'); and removing the mould from the mould form (11) .

.IS A mould according to claim 11, characterized by solving a small amount of a water surface tension reducing agent (4) to the water (2) , forming a water solution (2) .

it. A mould according to claim 13, characterized by adding reinforcing fibres (3) into the mixer (5) during preparation of the batch of moulding mass (14) .

t"3. A mould according to claim 15, characterized in transfering the vacuum tob (7) to a rolling bed (7c) for rotation for evacuation of entrapped air bubbles from the batch of moulding mass (14) before injection into the mould form.

t .2 . A mould according to claim 13, characterized in that the mould form (11) is set under vacuum at least before and preferrably during transfer of the moulding mass (14) from the tob (7) . l^. A mould according to claim 13, characterized by internal mould channels (16) .

ϋD . A mould according to claim 13, characterized by integrated electrical heater circuits (17) .

_c l . A mould according to claim 13, characterized by internal mould reinforcement metal bars (18) .

, ,. A mould according to claim 13, characterized by external support beams (19) .

. A mould according to claim 13, characterized by a piston ejector (24) for releasing and ejecting the moulded, hardened product.