WO2016117688A1 - 鋳込成形体とその製造方法 - Google Patents

鋳込成形体とその製造方法 Download PDF

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Publication number
WO2016117688A1
WO2016117688A1 PCT/JP2016/051872 JP2016051872W WO2016117688A1 WO 2016117688 A1 WO2016117688 A1 WO 2016117688A1 JP 2016051872 W JP2016051872 W JP 2016051872W WO 2016117688 A1 WO2016117688 A1 WO 2016117688A1
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Prior art keywords
water
cast
mold
casting mold
casting
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PCT/JP2016/051872
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English (en)
French (fr)
Japanese (ja)
Inventor
彰夫 松本
欣史 三澄
慎吾 笠原
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Toto株式会社
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Priority to JP2016570725A priority Critical patent/JPWO2016117688A1/ja
Publication of WO2016117688A1 publication Critical patent/WO2016117688A1/ja

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    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor

Definitions

  • the present invention relates to a cast body of ceramic powder or metal powder and a manufacturing method thereof.
  • Casting is a process in which a slurry containing a mixture of powder and solvent is poured into a casting mold having a porous layer, and the porous layer absorbs a part of the solvent and solidifies (this is applied to the wall). To produce a cast molded body. Cast-in molding is frequently used as a molding method for large complex shaped members such as sanitary ware and large engineering ceramic members.
  • water is described as a specific example of the solvent, an organic solvent can be used in addition to water. Accordingly, the water absorption includes absorbing an organic solvent.
  • the driving force that moves the water in the slurry to the porous layer of the casting mold is called casting pressure.
  • the casting pressure can be determined by adding the capillary suction force of the porous layer, the direct pressure applied to the slurry, the head pressure of the slurry, the suction force when the porous layer is sucked with a vacuum pump or the like.
  • capillary suction force or direct pressure on the slurry is mainly used, and the head pressure and suction force of the slurry are used as an auxiliary role because their absolute values are small.
  • pressure casting by direct pressurization of mud has a high initial cost because the mold and molding machine must be pressure resistant, and can only be applied to very high-volume products. Therefore, the capillary suction force of the porous layer is mainly used as the casting pressure of ordinary casting.
  • gypsum has been used as a material for the casting mold (hereinafter also referred to as a mold material).
  • a mold material a material for the casting mold
  • the reason is that it is inexpensive and the molding is simple, but it can be considered that it has the following two advantages.
  • the first advantage is that it has self-water absorption.
  • Self-water absorption occurs when hemihydrate gypsum, which is a gypsum-type raw material, is hydrated and develops capillary suction due to entanglement of fine crystals of dihydrate gypsum. Therefore, since the casting mold itself develops the casting pressure, an expensive operation such as pressurization to the slurry is unnecessary.
  • the second advantage is that the releasability is excellent.
  • the releasability is manifested by peeling the surface of the molding surface of the casting mold together with the cast molding. Since gypsum is inferior in water resistance, its surface dissolves in water little by little, so it has excellent releasability.
  • the casting mold using gypsum has two advantages, that is, self-water absorption and excellent releasability, but there are also disadvantages. That is, since the surface of the molding surface of the casting mold is dissolved to exhibit the releasability, the surface wear becomes severe during many moldings. In addition, since the inside of the pores becomes water-soluble, the capillary diameter becomes large and sufficient capillary suction force is not expressed. Therefore, the die number (that is, the number of products that can be manufactured with one die) is only about 80 to 150 times. In addition, when a worn mold is used, the quality of the cast product is lowered, and the yield is lowered. In addition, cuts frequently occur due to shrinkage in the earth tightening process and drying process after the meat is finished, leading to cracks in the molding process and firing process.
  • Cast-in molding is suitable for molding products with large and complex shapes because it allows the shape of the casting mold to be faithfully copied by pouring fluid mud into the casting mold.
  • the capillary suction force of gypsum is determined by the capillary diameter of the gap between the entanglements of dihydrate gypsum crystals.
  • This dihydrate gypsum crystal is due to the precipitation of dihydrate gypsum from the hemihydrate gypsum slurry, and its capillary diameter is very difficult to control, and the capillary diameter cannot be controlled over a wide range.
  • the pressure applied to the slurry is always constant according to Pascal's principle, so the casting pressure is constant in every part, and a cast product with a partially changed thickness is produced. I can't do it. Therefore, even if pressure is applied to the slurry by pressurizing with the piston or by bringing pressurized air into contact with a part of the slurry, the casting pressure is constant in any part.
  • the following methods are known as methods for producing cast-molded bodies having partially different thicknesses by casting.
  • Patent Document 2 discloses a method in which, in the exhaust mud casting method, a weir is provided in a portion where a thick-walled structure is desired after the first inking, and mud is injected into the weir for the second inking. Is described.
  • Patent Document 3 describes a method in which, in a waste mud casting molding method, a pressure in a cavity filled with mud is changed depending on a position by using a casting mold having a difference in solvent absorption capacity. .
  • Patent Document 4 a small piece of reaction-sintered ceramics is filled in a casting mold, and then a raw material slurry is cast, and the small piece absorbs the water of the slurry to produce a molded body partially different in thickness. How to do is described.
  • Patent Document 1 has a large difference in the filling rate of each part of the cast molded body, and thus there is a possibility that many cuts may occur in the molding process and the firing process.
  • the method of patent document 2 has a problem that it cannot respond to solid casting. There is also a problem that there is a restriction on the shape of the cast molded body because the portion to be thickened is formed after the first inking.
  • Patent Document 3 has a problem that it is difficult to carry out because it does not specifically describe a casting mold having a difference in solvent absorption capacity and means for changing the pressure depending on the position.
  • Patent Document 4 There is a problem that the method of Patent Document 4 cannot be applied to materials other than reaction sintered silicon nitride.
  • the present invention has been made in order to solve the above problems.
  • the present invention provides a cast molded body having a uniform filling rate and no breakage, and a cast molded body having a partially different thickness.
  • the purpose is to manufacture.
  • the cast product of the present invention is a cast product of ceramic powder or metal powder, characterized in that the difference in filling rate in the thickness direction is 0.05 or less. To do.
  • the cast molding of the present invention is a ceramic powder or metal powder cast molding partially different in thickness, and the ratio of the thickness of the adjacent thick portion to the thickness of the thin portion is 1.25. It is characterized by being not less than twice and not more than 5 times.
  • FIG. 4 is a conceptual diagram of a rib structure molded body that was molded in the present invention and did not break even when left in a mold for a long period of time.
  • the cast molded body of the present invention is a cast body of ceramic powder or metal powder, and the difference in the filling rate in the thickness direction is 0.05 or less, more preferably 0.025 or less.
  • the filling rate of the cast molded body is the volume fraction of the powder occupied in the cast molded body after the cast molded body is dried.
  • the filling rate of the cast molded body is the volume fraction of the powder occupied in the cast molded body after the cast molded body is dried.
  • a cast molded body having a filling rate of 0.6 indicates that the constituent components of the cast molded body are 60 vol% powder and 40 vol% air.
  • the cast molding usually has a distribution in the filling rate in the thickness direction, and here, the difference in the filling rate in the thickness direction in the present invention is defined as follows.
  • the first is solid casting which allows the mold to absorb water from both sides of the cast body. This is also called double molding, and the part molded by this is called a double part.
  • the cast molded body is sliced into five layers with a uniform thickness in the thickness direction, the respective filling rates are measured, and the portion showing the maximum filling rate (usually one layer in contact with the casting mold)
  • the difference between the filling ratio in the thickness direction is defined as the difference between the portion having the minimum filling rate (usually the third layer in the center) and the portion having the minimum filling rate.
  • the second is waste mud casting in which excess mud is discharged after water is absorbed into the mold from one side of the cast molding.
  • This is also referred to as single molding, and a portion molded by this is called a single molding.
  • the single part the remaining 80% thickness portion, excluding the portion corresponding to 20% of the thickness as a drainage portion with a large error, is sliced into 5 layers and the respective filling rates are measured, and the maximum filling rate is determined.
  • the difference between the portion shown (usually the first layer in contact with the mold) and the portion showing the minimum filling rate (usually the fifth layer close to the drainage surface) is defined as the difference in filling rate in the thickness direction.
  • many sanitary ware obtained by casting molding includes both a double part and a single part.
  • the filling rate of each part can be calculated
  • the filling rate is measured as follows. After the cast molding is completely dried at 120 ° C. (when the solvent is not water, the drying temperature is selected according to the boiling point of the solvent), the filling rate is measured by the Archimedes method.
  • the filling rate of the cast molded body may be measured from a fired body obtained by firing the cast molded body.
  • a fired body obtained by firing the cast molded body.
  • the shrinkage during firing is almost zero. Therefore, if the volume ratio of each layer is obtained by observing the fired body with a scanning electron microscope (SEM) and the components constituting each layer are identified by X-ray diffraction (XRD) or Raman analysis, the filling rate of the cast molded body Can be obtained by calculation.
  • the difference in the filling rate in the thickness direction of the cast molded body is 0.05 or less.
  • the drying shrinkage in the mold can be made as small and uniform as possible.
  • the difference in filling rate in the thickness direction is 0.025 or less.
  • the difference in filling rate can be set to 0.01 or less.
  • the difference in the filling ratio in the thickness direction varies depending on the type of the substrate, and the difference in the filling rate tends to be larger in the fine ceramic substrate than in the substrate containing a large amount of clay such as a ceramic substrate.
  • the base material is substantially the same material, the base material whose plasticity is improved by adjusting the density or the like has a high compressibility, and therefore there may be a large difference in the filling rate in the thickness direction.
  • the present invention as a preferable means of setting the difference in the filling ratio in the thickness direction of the cast molded body to 0.05 or less, more preferably 0.025 or less, it has self-water absorption and substantially water resistance.
  • Means for producing a cast molded body by a casting mold having a water absorbing layer can be mentioned.
  • the casting mold of the present invention includes a water absorbing layer.
  • the water absorbing layer having “self-water absorbing property” means that the water absorbing property can be expressed by the capillary suction force of the water absorbing layer itself. is there.
  • substantially water resistance means that it does not dissolve in water or react with water.
  • a substantially water-resistant water-absorbing layer refers to a material that exhibits releasability when the surface dissolves in water, such as a gypsum mold, and a hydraulic material as a material for forming the water-absorbing layer. It means that it was not obtained using a material that reacts with water.
  • a water-absorbing layer formed using a material that dissolves in water or reacts with water is not preferable because the surface of the water-absorbing layer deteriorates as the number of lives increases, and problems such as cracks and poor tightening occur.
  • the casting mold of the present invention includes a water-absorbing layer having self-water absorption and substantially water resistance. More preferably, the water-absorbing layer of the casting mold has a porosity of 35 vol% or more and 50 vol% or less, an average pore diameter of 0.5 ⁇ m or more and 1.8 ⁇ m or less, and a particle size of 50% of the average pore diameter.
  • the continuous pore volume is characterized in that the cumulative pore volume from the particle size to 150% is 60% or more of the total pore volume.
  • porosity means the volume fraction of the pores of the water absorption layer, and is measured by the Archimedes method. It is also possible to measure the porosity with a mercury intrusion pore size distribution measuring device described later. The porosity values measured by both methods are almost the same.
  • the porosity of the preferred water absorbing layer is 35 vol% or more. Thereby, the productivity which can ensure a sufficient water absorption speed is obtained.
  • the absolute value of the filling rate of the cast molded body can be increased, and the partial difference in the filling rate of the cast molded body can be decreased, thereby improving the yield and reducing the shrinkage of firing.
  • the preferred water absorption layer has a porosity of 50 vol% or less. Thereby, sufficient mold strength is obtained, and the risk of breakage during molding or molding is reduced.
  • the “average pore diameter” means a pore diameter corresponding to a cumulative pore volume of 50% obtained using a mercury intrusion pore diameter distribution measuring device (commonly referred to as a porosimeter).
  • the average pore diameter of the preferred water absorption layer is 0.5 ⁇ m or more. More preferably, it is 0.7 ⁇ m or more. Thereby, the water permeation resistance of the casting mold can be reduced, and the water flow amount at the time of water film demolding described later can be sufficiently secured. Further, even if the mold number increases, clogging of the water absorption layer is less likely to occur.
  • the average pore diameter of a preferable water absorption layer is 1.8 micrometers or less. More preferably, it is 1.4 ⁇ m or less. Thereby, the capillary suction force can be sufficiently secured to improve the productivity. Further, the absolute value of the filling rate of the cast molded body can be increased, or the partial difference in the filling rate of the cast molded body can be decreased to improve the yield and reduce the firing shrinkage.
  • the ratio of the cumulative pore volume to the total pore volume from 50% of the average pore diameter to 150% of the average pore diameter (hereinafter also referred to as “V50-150”) is the above-mentioned method.
  • the cumulative pore volume from 50% to 150% of the determined average pore diameter (for example, 0.5 to 1.5 ⁇ m if the average pore diameter is 1 ⁇ m) refers to the ratio of the total pore volume.
  • the total pore volume refers to the sum of the volumes of all pore portions of the water absorption layer.
  • V50-150 is 60% or more. More preferably, it is 80% or more. Thereby, the balance of water absorption speed and water permeability at the time of water film demolding can be adjusted, and both productivity and demoldability can be set to appropriate values.
  • the upper limit of V50-150 is not limited and may be 100%, but 99% is the upper limit of the range that can be controlled with industrially inexpensive molding costs.
  • the casting mold of the present invention may be composed only of a water absorption layer.
  • the casting mold of this invention has a water absorption layer and a reinforcement layer, and this reinforcement layer may be formed in the back surface of a water absorption layer.
  • the back surface of a water absorption layer points out the surface on the opposite side to the wall surface (it is also mentioned a molding surface) among water absorption layers.
  • This reinforcing layer is formed to support and reinforce the water absorbing layer.
  • this reinforcing layer for example, concrete, FRP, FRC, metal, plastic, or the like can be used.
  • Such a reinforcing layer may be reinforced by inserting a reinforcing bar or the like.
  • examples of the material for forming the water absorption layer include a sintered metal mold, a ceramic mold, and a resin mold.
  • the manufacturing principle and pore structure creation principle of sintered metal molds and ceramic molds are almost the same.
  • Metal particles and ceramic particles are molded into a water-absorbing layer shape, and the molded body is sintered to fuse the particles together.
  • the gap can be a pore.
  • the porosity and pore size distribution can be controlled by controlling the particle size, sintering temperature, and sintering time of the particles.
  • the pore size of the particles is reduced, the pore size is also reduced, and if the particle size distribution of the particles is sharpened, the pore size distribution is also sharpened.
  • the porosity is determined by the porosity inherent in the compact of metal particles / ceramic particles and the degree to which the pores are closed by sintering. Therefore, if the compact filling factor is small, the porosity is large, and if the sintering temperature is high and the sintering time is long, the porosity is small. In a preferable range of the porosity of 35 vol% or more and 50 vol% or less, it is desirable to reduce the shrinkage caused by the progress of sintering by making the compact filling rate as close as possible to the target filling rate.
  • water-resistant metal particles and ceramic particles that are raw materials for sintered metal molds and ceramic molds, and the sintered metal molds and ceramic molds that are sintered thereby must also be water resistant. Can do. Also, when using auxiliary materials / additives at the time of molding / firing as raw materials, water-resistant auxiliary materials / additives must be used unless they are volatilized during sintering or change to water-resistant components. Don't be.
  • the mold strength may not be sufficiently secured. Many. Therefore, firing shrinkage often occurs in sintered metal molds and ceramic molds, but it may be technically difficult to obtain dimensional accuracy of the mold due to the firing shrinkage.
  • the resin mold does not have a sintering process, it has a merit that it is easy to obtain dimensional accuracy and can be formed by pouring a material for forming the mold.
  • the sintered metal mold and the ceramic mold are superior to the resin mold, and thus have advantages and disadvantages.
  • the resin itself must not dissolve or react with water, and as a resin mold raw material, use a filler that dissolves in water or reacts with water. Must not. Therefore, do not use water-soluble ones such as gypsum, or ones that react with water, such as alumina cement or Portland cement.
  • a filler having substantially water resistance the water resistance of the water absorbing layer can be improved.
  • fillers having substantially water resistance such as silica sand, silica powder, alumina, zircon, glass beads, glass balloon, glass cullet, and frit glass can be preferably used.
  • the glass must not dissolve in water as a glass composition.
  • the molding surface which has water resistance can be formed, and it becomes possible to prevent generation
  • resin-type water-absorbing layers including emulsion polymerization from O / W type emulsion slurry, method of inversion emulsion polymerization from W / O type emulsion, solvent
  • a method of mixing a soluble component in a raw material and removing the soluble component with a solvent after curing can be given.
  • an O / W type emulsion slurry in which a resin phase (oil phase) is dispersed in an aqueous phase is prepared, and this O / W type emulsion slurry is cast into an impermeable mold and cured in a water-containing state.
  • this method the portion of the aqueous phase that is a continuous layer becomes continuous pores, and thus the porosity can be controlled by controlling the amount of water in the emulsion slurry.
  • the pore size distribution of the created water-absorbing layer porous body can be adjusted. It can also be controlled.
  • the pore size distribution of the water-absorbent layer porous body created can be controlled by controlling the filler particle size distribution. You can also By using these molds, the filling rate of the cast molded body can be made uniform. Therefore, it is possible to prevent the cast molded body from being cut at the time of casting, and to increase the yield.
  • the reason why such an effect can be obtained is considered as follows, but is not limited thereto. It is considered that the filling rate of the cast-molded body is determined by the compression pressure at the time of inking. Since the casting mold of the present invention has self-water absorption and substantially water resistance, it is considered that pressure loss on the molding surface can be reduced at the time of fleshing. Therefore, it is considered that the filling rate of the cast molded body can be made uniform.
  • the compression pressure applied to the molded body at the time of fleshing is also a function of the pressure loss in the molded body determined by the capillary suction force determined by the porosity and pore size distribution of the water-absorbing layer and the filling rate distribution of the molded body,
  • pressure loss does not occur on the wall surface, and for this purpose, a water absorbing layer is formed so that a heterogeneous layer due to dissolution of the mold material cannot be formed on the mold surface. It is thought that the material constituting the water must be water resistant.
  • the water absorption layer itself must be considered in terms of strength, ventilation and water permeability when removing the water film.
  • a water absorption layer with a very small pore diameter to obtain a strong capillary suction is Aeration and water permeability are poor.
  • the casting mold of the present invention can be provided with means for supplying pressurized water or pressurized air.
  • Specific means for supplying pressurized water or pressurized air include a method of providing an air groove inside or on the back surface of the water absorption layer, a method of providing a coarse porous layer on the back surface of the water absorption layer, and the like.
  • Examples of the case where pressurized water or pressurized air is supplied to the casting mold include the following cases.
  • the water film mold release which applies a back pressure to a casting mold and blows out water and air between a casting mold and a molded object and demolds is mentioned. In this case, it is usually preferable to supply pressurized air to the water absorption layer.
  • the sealing layer can be formed by applying a material such as resin on the back surface of the casting mold and curing it.
  • a reinforcing layer of the sealing layer may be provided on the outside of the sealing layer with FRP, concrete, FRC, metal, plastic, or the like.
  • the method for preventing the occurrence of breakage during molding by setting the difference in the filling rate in the thickness direction of the cast molded body to 0.05 or less, more preferably 0.025 or less has been described.
  • the following steps (1) to (4) are carried out in this order, whereby a difference in filling rate of each part of the cast molded body is small.
  • a molded body can be manufactured.
  • (1) The step of controlling the water saturation of the water-absorbing layer having self-water absorption and substantially water resistance (2)
  • the step of casting slurry in the casting mold (3) The slurry in the casting mold
  • step (4) (a) a step of discharging excess slurry, and (b) a step of increasing the hardness by reducing the moisture content of the waste mud surface of the formed body. These steps can also be performed in this order.
  • the step of controlling the water saturation rate of the water absorbing layer is a step of adjusting the water saturation rate of the water absorbing layer so that the deposition rate falls within an industrially appropriate range.
  • the water saturation is preferably 30 to 80%, more preferably 40 to 60%.
  • the rate of fleshing can be increased.
  • the water saturation rate can be finely adjusted depending on the base for forming the cast molded body and the molding conditions. As a specific method for adjusting the saturation rate, the saturated water rate is almost 100% by injecting pressurized water into the casting mold until the desired saturation rate is obtained by injecting pressurized air thereafter.
  • the saturation rate is calculated assuming that the saturation rate is 100% when the pores of the water absorbing layer are completely filled with water.
  • the step of casting slurry in the casting mold is a step of casting slurry in the casting mold in which the saturation rate is controlled in this way.
  • the step of depositing the slurry in the casting mold is a step of forming part of the slurry by solidifying the slurry by absorbing a part of the water contained in the slurry into the water absorption layer.
  • the capillary suction force of a water absorption layer is made into the driving force of the main meat
  • Another force may be used as a casting pressure for assisting the capillary suction force of the water absorption layer.
  • a means for supplying pressurized water or pressurized air can be provided in the casting mold, and vacuum suction can be performed through the means.
  • a peeling phenomenon may occur at the time of demolding in the next step. Therefore, it is preferable to stop the vacuum suction when the deposition time is 60 to 90%. Moreover, you may use the pressure (henceforth a head pressure) at the time of supplying mud from a pouring opening to a casting mold as casting pressure. Normally, since the head pressure is used as the pouring pressure into the slurry mold, this head pressure can be used as the casting pressure as it is.
  • the slurry can be directly pressurized with a pump, piston, etc. in the process of depositing the slurry on the casting mold, but if this direct pressure is applied, the mold and molding apparatus must be pressure resistant and the cost is low. It becomes a factor of up. Since the present invention uses the water absorption force of the casting mold itself as the main driving force for the inking, it is preferable not to perform such direct pressure.
  • the water absorption layer is open to the atmosphere including the earth closing time described below.
  • a means for releasing the water absorption layer to the atmosphere there is a method of releasing the water absorption layer to the atmosphere by providing the above-mentioned means for supplying pressurized water or pressurized air to the casting mold and providing a pipe for opening the atmosphere to this means. it can. Therefore, it is preferable to provide the casting mold with means for performing a switchable operation of any one of (1) supply of pressurized water, (2) supply of pressurized air, (3) vacuum suction, and 4) release to the atmosphere. .
  • the demolding time may be immediately after the end of the meat filling, or the mold can be demolded after a soiling time.
  • the earth closing time is usually essential. By using means such as supplying pressurized air into the sludge space, a soil closing time is taken until a predetermined hardness is obtained.
  • solid casting there is almost no shrinkage of the molded body during the earthing time, and no tightness occurs, so the earthing time is almost unlimited and may or may not be present.
  • a preferable method for demolding includes water film demolding in which water is jetted between the mold and the molded body by supplying pressurized air or pressurized water to the mold.
  • the difference in the thickness direction of the change from the end of the filling to the time of demolding is more preferably 0.05 or less by controlling the soil closing conditions. Is preferably 0.025 or less.
  • the filling rate at the time of finishing the meat and at the time of demolding is the same definition as the filling rate when the molded body has been completely dried as described above, and only the part of the volume fraction other than the powder. Is the difference between air and water.
  • the molded product at the end of the fleshing with a filling rate of 0.6 or at the time of demolding refers to that whose constituent fraction is 60 vol% of powder and 40 vol% of water.
  • the measurement method is such that water is completely dried and the weight change is measured, and the volume fraction is calculated in consideration of the specific gravity difference between the powder and water.
  • the finishing time is set to the time when the head drop during solid casting is substantially stopped.
  • the term “substantially” as used herein refers to the time point when the molding has finished being thinned and the head drop is almost zero, and thereafter the head is lowered slightly due to the filling of the pouring port other than the molded article. It may continue. Also, since it may take some time to remove the molded product from the mold immediately after the end of the inking, the measured part is cut out from the formed body 5 minutes after the end of the inking to measure the filling rate. Thus, this is defined as the filling rate at the end of the inking.
  • the time of demolding shall cut a measurement part from the molded object immediately after demolding, and shall measure a filling rate.
  • the difference in the change in the thickness direction of the filling rate is defined in the same manner as the difference in the thickness direction of the filling rate when the molded body is completely dried. That is, the measurement part of the molded body at the end of the inking or at the time of demolding is sliced into five layers, and the respective filling rates are measured and evaluated.
  • the difference in the thickness direction of the change in the filling rate from the end of the bedding to the time of demolding is, for example, 0.55 to 0. If it is changed to 6, the difference is 0.05, and if it is normally changed from 0.5 to 0.58 in the third largest layer, the difference is 0.08. Therefore, the difference in the thickness direction of the change in the filling rate from the end of the infilling to the demolding in this case is 0.03 obtained by subtracting 0.05 from 0.08.
  • the tightening at the time of earth closing is controlled by controlling the preferable value of the difference in the thickness direction of the change from the end of the filling to the time of demolding to 0.05 or less, more preferably 0.025 or less.
  • the occurrence of cutting can be prevented more reliably.
  • there is no preferred lower limit of the difference in the thickness direction of the change from the end of the filling rate to the time of demolding it is industrially difficult to make it 0.001 or less.
  • This preferred range is the same in all double parts as well as the double part close to the single part of the molded article having the single part and the double part, but the double part close to the single part is usually the most. Since the difference is large, this part is evaluated.
  • control method of the earthing conditions for setting the difference in the thickness direction of the change in the filling rate of the double part from the end of the inlay to the time of demolding is 0.05 or less, more preferably 0.025 or less. It refers to such means.
  • pressurized air is often supplied to the waste mud space mainly to harden the part of the single part that is particularly close to the sludge discharge surface.
  • the pressure air pressure can be reduced to increase the pressurized air charging time.
  • pressurized air is supplied only to the first part during soiling, and then the mud space is returned to atmospheric pressure.
  • a technique of leaving the mold in the mold until it is slightly below the upper limit of the preferable range can also be used, which is effective when the molded body is left in the mold at night.
  • a cast body of ceramic powder or metal powder according to the present invention wherein the difference in filling rate in the thickness direction is 0.05 or less, more preferably 0.025 or less.
  • the molded body and its manufacturing method have been described. As described above, this is achieved by reducing the difference in the filling rate of each part of the molded body during molding and reducing the tensile stress due to the difference in drying shrinkage of each part. Its purpose was to prevent cutting.
  • the cast molding with a small difference in the filling rate in the thickness direction and the manufacturing method thereof can exert a greater effect in the production of cast ceramics or metal powders with partially different thicknesses. Is possible. This is because, in cast moldings with partially different thicknesses, there is a large difference in the filling rate of the parts with different thicknesses, and there is a step at the boundary between the parts with different thicknesses. This is because it is more likely to occur.
  • Examples of a method for producing a cast product having a partially different thickness include a method of using a water absorption layer having a difference in the thickness of the part in a casting mold.
  • As an index representing the inking speed there is the inking speed constant, which is a value obtained by dividing the square of the inking thickness by the inking time, and is a constant that does not depend on the inking time.
  • the inking phenomenon in casting is, in principle, a cake filtering operation, and the inking rate constant is proportional to the casting pressure.
  • the square root of the capillary suction force can be approximated to the wall thickness within a certain time. The thickness of each part of the molded body can be adjusted.
  • the uniformity of the filling rate of the part is also important, and preferably the difference in the filling rate between the adjacent thick part and the thin part is 0.05 or less. It is possible to keep the adjacent thick and thin portions within the preferred range by being manufactured by a casting mold having a water-absorbing layer having self-water absorption and substantially water resistance, The reason is the same as the reason why the filling rate in the thickness direction is uniform.
  • the wall thickness is different, the compression pressure distribution in the molded body is different and the hurdle is further increased, so that the present invention can be suitably applied.
  • the casting mold is configured as a plurality of split molds, and the water absorption layers of the plurality of split molds have different thicknesses. It is preferable that When it is configured as a split mold, a mold material having water resistance as in the present invention is preferable because the mold mating surface is hardly worn.
  • FIG. 1 and FIG. 2 show specific examples of casting molds configured as a plurality of split molds and having different splitting rate.
  • FIG. 1 shows a split mold having a water absorption layer 2 (hereinafter referred to as a high-thickness type water-absorbing layer) having a high flaking rate and a water-absorbing layer 1 (hereinafter referred to as a low-thickness type water-absorbing layer) having a low flaking rate.
  • a cast molded body 3 is formed by exhaust mud casting using a casting mold having a split mold having a slag. Thereby, it is possible to obtain a hollow cylindrical cast body having a partially different thickness.
  • FIG. 2 is a specific example in which a cast molded body 3 is formed by solid casting using a casting mold having a high-walled water-absorbing layer 2 and a low-walled water-absorbing layer 1. . Thereby, the cast molding which has a rib structure from which thickness differs partially can be obtained.
  • the casting mold has a plurality of water absorption layers, and the plurality of water absorption layers have different thicknesses. It is preferable. In this case, it is possible to integrate and use a plurality of water-absorbing layers each having a different deposition rate. Using a plurality of water absorbing layers with different inking speeds in an integrated manner means that a plurality of water absorbing layers with different inking speeds are integrated so that the forming speed is partially different on the molding surface. Refers to that. As a result, cracks and the like due to the mold-joining surface are less likely to occur. FIG.
  • FIG. 3 shows a specific example of a casting mold for waste mud casting in which a plurality of water absorption layers having different thicknesses are integrated.
  • the casting mold shown in FIG. 3 is a specific example of a casting mold in which the high-walled mold water-absorbing layer 2 and the low-walled mold water-absorbing layer 1 are integrated. Thereby, the cast molding from which thickness differs partially can be obtained.
  • the following methods can be used to integrally form the water-absorbing layers having different thicknesses.
  • sintered metal molds and ceramic molds a plurality of ceramic powders and metal powders having different particle size distributions are used as raw materials, and after filling one raw material powder into a mold, the other raw material powder is filled, and then integrally A technique for sintering is mentioned.
  • the resin mold since the raw material slurry is often a liquid, the following method is used. First, the resin mold slurry for forming the first water-absorbing layer is cast into an impermeable mold, and after the resin mold slurry loses fluidity, the second resin mold slurry is poured before it is completely cured. Mold and cure in one piece.
  • the joint between the two types of resin molds may have insufficient strength.
  • the joint surfaces of the two types of resin-type water-absorbing layers are lower than the strength of the respective water-absorbing layers. Therefore, after the surface of the first water-absorbing layer is roughened or uneven, It is preferable to take a method of pouring a resin type slurry for forming a water absorption layer.
  • the following method can be used to integrally form the water absorption layers having different deposition rates for sintered metal molds and ceramic molds.
  • a water absorption layer having a large flaking rate uses a metal powder or ceramic powder having a small particle size as a raw material
  • a water absorption layer having a small flaking rate uses a metal powder or ceramic powder having a large particle size as a raw material.
  • a metal powder molded body or a ceramic powder molded body using each powder is integrally molded or joined and sintered simultaneously.
  • a method of integrally molding a metal powder molded body or a ceramic powder molded body As a method of integrally molding a metal powder molded body or a ceramic powder molded body, a method is adopted in which after molding one molded body and placing the molded body in a mold, the other molded body raw material is cast. be able to. Moreover, you may join both the molded objects using the adhesive paste which added the adhesive agent, the solvent, etc., and was made into the paste-like form, and a component is substantially equal to each molded object. Further, it is possible to join the sintered metal water absorption layer or the ceramic water absorption layer after sintering if the bonding strength is not so required.
  • the above-described water absorbing layer used in the casting mold of the present invention can be used. This is because the above-mentioned water absorption layer used in the casting mold of the present invention can be controlled in a wide range of the rate of walling, and thus is suitable for producing molded bodies having partially different thicknesses.
  • a means for controlling the capillary suction force of the water-absorbing layer may be mentioned as a means for controlling the rate at which the water-absorbing layer is deposited. Since the capillary suction force of the water absorption layer is inversely proportional to the tube diameter, the capillary suction force can be adjusted by controlling the pore diameter of the water absorption layer porous body.
  • Examples of means for controlling the capillary suction force of the water-absorbing layer include the above-mentioned means for controlling the pore diameter of the water-absorbing layer, and control within a preferable pore diameter range of 0.5 ⁇ m to 1.8 ⁇ m. Can do.
  • the water absorption layer has a partially different walling speed. It is possible to produce cast moldings having different thicknesses. By using such a casting mold, it is possible to obtain a cast molded body with a uniform filling rate. Variations in drying shrinkage and firing shrinkage of the portion can be reduced. Therefore, generation
  • any kind of powder can be used for the cast-molded body in the present invention.
  • what is important as an industrial application field is a cast body of ceramic powder or metal powder.
  • the cast molding obtained by casting molding powder can be baked, and can be utilized as a sintered body.
  • Ceramics powders for the production of ceramics such as sanitary ware, tableware, insulators, tiles, mixed powders such as silica sand, feldspar, clay, alumina, silicon carbide, silicon nitride, boron carbide, aluminum nitride, sialon, zirconia Monolithic ceramic powders such as mullite, and composite ceramic powders obtained by mixing them can be used.
  • powder for producing a reaction sintered body such as reaction sintered silicon carbide, a reaction sintered silicon carbide and boron carbide composite, reaction sintered silicon nitride, or the like can also be used.
  • Metals include pure iron, iron-copper, iron-carbon, iron-carbon-copper, iron-carbon-copper-nickel, iron-carbon (copper infiltration), iron-nickel, iron -Carbon-nickel, iron-nickel-molybdenum-carbon, iron-manganese-chromium-carbon, iron-copper-nickel-molybdenum-carbon, stainless steel, high-speed steel, pure copper, bronze, brass, silver, aluminum Bronze, silgin bronze, nickel bronze, phosphor bronze, monel, temperloy, aluminum and its alloy, titanium and its alloy, superalloy, tungsten and its alloy, cemented carbide, cermet and the like can be used.
  • the cast molded body when the cast molded body is fired and used as a fired body, since the cast molded body has a high filling rate and a uniform filling rate of each part of the cast molded body, the shrinkage during firing is small. It becomes possible for the part to shrink uniformly. Therefore, there are advantages in that cracks due to firing hardly occur and that dimensional stability is high.
  • the cast molding has a high filling rate and the filling rate of each part is uniform, so that the sintering proceeds sufficiently. It is easy, and physical properties such as strength after sintering can be made high and uniform.
  • the mold design is such that the inking is completed at approximately the same time for each part with different thickness of the cast molding Is preferably performed.
  • the thickness ratio between the adjacent portions is not more than 5 times that of the thin portion.
  • the thickness of the thick part is 1.25 times that of the thin part. The above is preferable. More preferably, it is 1.5 times or more.
  • the ratio of the thickness between the double parts there is a preferable range and a high practical range in the single part of the sludge cast molding as well.
  • the ratio of the thickness of the adjacent part is The thick part is preferably 4 times or less than the thin part.
  • the boundary between the portions having different thicknesses becomes a gentle R portion. Therefore, by joining three or more layers of water absorbing layers having different thicknesses, the above-mentioned 2 through the almost continuous smooth R portion.
  • the molded body can also be designed so as to have a thickness ratio of 5 times or more, which is a preferable upper limit thickness ratio of the heavy portion. The preferred lower limit is the same as in the case of solid casting.
  • sanitary ware In these powder sintered bodies, if there are portions having different thicknesses, sanitary ware, engineering ceramics, and the like are preferable examples.
  • the thickness of the trap part In sanitary ware, the thickness of the trap part is controlled to control the flow of cleaning water, and only the parts that are likely to be fired and deformed are thickened and the remaining parts are thinned to create a sharp shape and design. It is possible to reduce the weight.
  • engineering ceramics it is possible to reduce the weight by controlling the thickness to ensure the strength of the necessary part.
  • translucent ceramics such as a metal halide lamp, the functions of brightness and productivity can be achieved by controlling the thickness of the light emitting portion and the sealing portion.
  • the present invention also relates to a casting apparatus for ceramic powder or metal powder, comprising a molding machine capable of performing each step of the above-described method for producing a cast molded body, and the above casting mold. Providing casting equipment.
  • Tables 1 and 2 show physical properties of casting molds 1 to 21 used as examples and comparative casting molds 1 to 8 used as comparative examples.
  • the raw materials used for the casting molds 1 to 21 are a water-resistant epoxy resin and a water-resistant filler.
  • the fillers used are casting molds 1 to 14 and casting molds 17 to 21 are silica sand powder, and casting molds 15 and 16 are alumina.
  • the casting mold 1 for a comparative example is a gypsum mold that is usually used industrially, and is a gypsum mold that is manufactured using ⁇ -type hemihydrate gypsum manufactured by San-S Gypsum Co., Ltd.
  • the raw material used for the casting molds 2 and 3 for comparative examples is a mixture of a water-resistant epoxy resin mixed with a water-resistant filler and a non-water-resistant filler.
  • silica sand is used as the filler having water resistance
  • hemihydrate gypsum is added as a raw material in the casting mold 2 for the comparative example
  • Portland cement is used as the raw material in the casting mold 3 for the comparative example as the filler having no water resistance.
  • the raw materials used for the comparative casting molds 4 to 8 are a water-resistant epoxy resin and a water-resistant filler.
  • the casting molds for comparative examples 4, 5, 6, and 8 are silica sand powder
  • the casting mold for comparative example 7 is alumina.
  • a test piece having a head speed of 2.5 mm / min was vacuum-sucked for 30 minutes, then submerged and further vacuum-suctioned for 30 minutes.
  • the inking rate constant A (10 ⁇ 2 mm 2 / sec) was calculated by the following method. 1) A 100 mm ⁇ ⁇ 30 mmt casting mold test piece was adjusted to have a saturation rate of 50%. 2) An acrylic tube with a diameter of 60 mm was set up on the test piece, and Vitreas China sludge (specific gravity 1.8) for large sanitary ware was poured into the acrylic tube to a depth of 50 mm.
  • the inking rate constant B (10 ⁇ 2 mm 2 / sec) is 3) in (Note 5), from 1 minute after the start of the inking time to 85% of the inking time t, that is, 0. Calculations were made in the same manner as in (Note 5) except that the test piece was vacuumed up to 85 ⁇ t seconds. During vacuum suction, the pressure between the vacuum pump and the test piece was set to 0.01 to 0.015 MPa.
  • the inking rate constant C (10 -2 mm 2 / sec) is the same as in (Note 5) 2) except that high-purity alumina slurry (specific gravity 2.5) for large products is used as the slurry (Note 5). ).
  • the inking rate constant D (10 -2 mm 2 / sec) is the same as that in (Note 5) 2) except that iron powder slurry (specific gravity 4.2) is used as the slurry. Calculation was performed in the same manner as in 5).
  • the amount of water flow was measured by the following method. 1) In a casting mold test piece of 100 mm ⁇ ⁇ 30 mmt, the side surface was completely sealed so that water did not come out from the side surface, and then completely saturated. Here, the completely saturated state refers to a state in which all pores are filled with water. 2) A water pressure of 0.3 MPa was applied from one end, and the amount of water discharged from the other end until 15 seconds after the start of applying the water pressure was measured.
  • the test piece was vacuum sucked from 1 minute after the start of the setting time to 85% of the setting time.
  • the pressure during vacuum suction was such that the pressure between the vacuum pump and the test piece was 0.01 to 0.015 MPa.
  • the test piece was dried at 40 ° C. for 24 hours before pouring the slurry.
  • the casting mold 7, and the comparative casting mold 6, the saturation rate was adjusted to 50% before the slurry was poured. After completion of 20 mm thickening corresponding to the thickness of the PVC pipe, the mold was removed, and the molded body in the PVC pipe was dried at 40 ° C. overnight.
  • the molded body was removed from the polyvinyl chloride tube and dried at 120 ° C. for 12 hours. Thereafter, a cast molded body of 20 mm * 20 mm was cut out from the center part of the cast molded body having a thickness of 20 mm to obtain cast molded bodies of Examples 1 to 4 and Comparative Examples 1 to 4.
  • Each cast molding was sliced into five layers, and the filling rate was measured by Archimedes method.
  • the respective filling points are A, B, C, D, and E (where A and E are in contact with the mold and C is the central part), and the obtained filling rate and the maximum and minimum values of the filling rate obtained. The difference in values is shown in Table 3.
  • Test pieces of 100 mm ⁇ ⁇ 30 mmt were prepared using the mold materials of the casting mold 4, the casting mold 7, the comparative casting mold 1, and the comparative casting mold 6.
  • the saturation rate was adjusted to 50% before the slurry was poured.
  • the test piece was dried at 40 ° C. for 24 hours before pouring the slurry.
  • a 60 mm ⁇ acrylic tube was erected on each test piece, and slurry was poured into the acrylic tube to a depth of 50 mm.
  • the test piece was vacuumed from 1 minute after the start of the setting time to 85% of the setting time.
  • the pressure during vacuum suction was such that the pressure between the vacuum pump and the test piece was 0.01 to 0.015 MPa.
  • the saturation rate was adjusted to 50% before pouring the slurry.
  • the mold was removed, and the molded body in the PVC pipe was dried at 40 ° C. overnight. Thereafter, the molded body was removed from the polyvinyl chloride tube and dried at 120 ° C. for 12 hours.
  • Test pieces of 100 mm ⁇ ⁇ 30 mmt were produced in the following order using the casting mold 1 and casting mold 7.
  • a casting mold for producing a test piece of 100 mm ⁇ ⁇ 30 mmt was divided into a half-moon shape by a partition at the center, and a resin mold slurry as a raw material of the casting mold 1 was first cast on one side. Then, after the semi-cured state was reached in a state where water contained in the slurry did not evaporate, the partition was removed, and the resin-type slurry as the raw material of the casting mold 7 was cast on the other half-moon part. Thereafter, in a state where the water contained in the slurry does not evaporate, it was completely cured in a water-containing state, and after curing, it was demolded to obtain a test piece of a casting mold.
  • a test piece of 100 mm ⁇ ⁇ 30 mmt was produced by the same method using the mold materials of the comparative casting mold 6 and the comparative casting mold 7.
  • a 60 mm ⁇ acrylic tube was placed on each of the obtained test pieces, and Vitreas China sludge for large sanitary ware was poured into the acrylic tube to a depth of 50 mm (Note 5). When observed from the outside of the acrylic tube, it was allowed to stand on the casting mold 7 portion and the comparative casting mold 7 portion until it appeared to be 15 mm thick. After that, the unfilled mud was drained, and after casting, demolding and drying, a cast product was obtained. Moreover, the obtained cast product was fired at a normal firing temperature for sanitary ware having a maximum temperature of 1180 ° C. to obtain a fired body.
  • the cast moldings molded with the test pieces of the casting mold 1 and the casting mold 7 had no cracks or defects.
  • the filling rate of each part of the cast molding was measured, it was 0.649 in the casting mold 1 part and 0.67 in the casting mold 7 part. There were no cracks or defects in the fired body after firing.
  • the cast moldings molded with the test pieces of the comparative casting mold 6 and the comparative casting mold 7 are cracked and deformed on the joint surface of the mold, and the thickness is accurately increased. It was not possible to measure.
  • the filling rate of each part of the cast molding was measured, it was 0.613 for the comparative casting mold 6 and 0.668 for the comparative casting mold 7.
  • the thickness of the plate-like molded body was 5 mm for the casting mold 1 and 25 mm for the casting mold 7, and the thickness was varied with the center as the boundary.
  • the stepped portion at the boundary with different thickness was set to about 1.5 mmR.
  • a solid cast molding gypsum mold for molding a 200 mm ⁇ 200 mm plate-shaped cast molded body using the mold material of the comparative casting mold 1 was produced.
  • the thickness of the plate-like molded body was set to be different from the center as a boundary, so that the half was 10 mm and the other half was 12.5 mm.
  • the boundary between the portions having different thicknesses was set to about 1.5 mmR.
  • the cast solids were obtained by pouring the vitreous china sludge for large sanitary ware (Note 5) into each of the solid casting molds obtained.
  • the casting mold for producing the rib structure molded body shown in FIG. 4 has a casting mold 4 as a water-absorbing layer, a casting mold 7, a casting mold 1 for comparative examples, and a casting mold for comparative examples. Each was produced using the mold material of mold 6.
  • the casting mold 4, the casting mold 7, and the comparative casting mold 6 are vertically split and the rib portion is integrated with the upper mold, and the comparative casting mold 1 is vertically , It was divided into 8 parts with 2 sides and 4 ribs.
  • the demolding method is a casting mold 4, casting mold 7, and comparative casting mold 6 is a water film demolding method in which back pressure is applied to each split mold by pressurized air supply means. As for the casting mold 1, only the rib part was air-injected into the gypsum split mold.
  • the solid casting was performed using the high-purity alumina slurry for large products (Note 7) for each mold. After completion of the meat deposition, the soiling time was left under 5 conditions of 10 minutes, 30 minutes, 2 hours, 24 hours, and 72 hours, and then the mold was removed. The water-absorbing layer was opened to the atmosphere during the time of meating and soiling. As a result, in the casting mold 1 for the comparative example, undercut conditions occurred in almost all the corner R portions, and under the conditions of 10 minutes, the base was soft and deformed during demolding.
  • the corner R portion was not cut off only under the condition of 10 minutes of the earth tightening, but the base material was soft, so that deformation occurred at the time of demolding. Cutout occurred in almost all parts.
  • the casting mold 4 and the casting mold 7 no breakage occurred at all earthing conditions, and no deformation occurred at the time of demolding. And although the molded object obtained with the casting mold 4 and the casting mold 7 was dried and baked, the fault did not generate
  • the outer size is 300 mm x 300 mm x 80 mm, and the mold is placed so that the size in the vertical direction (gravity direction) is 80 mm at the time of molding. It has both a single part and a double part, and the thickness of the double part Is 10 mm, and the maximum thickness in the longitudinal direction (gravity direction) of the single-part sludge space is 64 mm when the single-part thickness is 8 mm.
  • Each was produced using the mold materials of the mold 4 and the casting mold 1 for the comparative example. Subsequently, a molded body was prepared by using water in which the specific gravity was set to 1.74 by adding water to the large sanitary ware vitreous china slurries of (Note 5).
  • the mud was drained after the single part was made to be 8 mm thick. Subsequently, the soil pressure was controlled by variously controlling the air pressure and the time to apply air pressure to the sludge space as the soil tightening conditions. No soil closing condition was found.
  • the cast mud 4 was used to drain the mud until the single part became 8 mm. Subsequently, as the soil tightening conditions, the air pressure and the time during which the air pressure was applied were variously controlled, and after performing the soil tightening under the condition that the deformation of the molded body did not occur at the time of the mold release, the mold was removed. A 10 mm ⁇ 10 mm molded body was cut out from a portion 5 mm away from the single part of the double part of the molded body immediately after demolding and sliced into 5 layers, and the filling rate was measured. In addition, each part shall be displayed in order as A, B, C, D, and E (the part where A and E are in contact with the mold is the top).
  • Table 6 shows the change in the filling rate distribution of each molded body at the time of soil tightening under the respective soil tightening conditions and the occurrence of the tightness of the molded body.
  • a cast-molded body having a uniform filling rate can be manufactured with a high yield. Moreover, the manufacturing method of the cast-molding body from which thickness differs partially can be provided.

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JPH05228913A (ja) * 1991-07-26 1993-09-07 Sumitomo Electric Ind Ltd セラミックスの成形法および装置
JPH06285825A (ja) * 1993-04-06 1994-10-11 Denki Kagaku Kogyo Kk 型材及び成形型の製造法
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JP2000061917A (ja) * 1998-08-24 2000-02-29 Mitsui Mining & Smelting Co Ltd Ｉｔｏ成形体およびその製造方法並びにｉｔｏ焼結体の製造方法
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JPS6375044A (ja) * 1986-09-17 1988-04-05 Toto Ltd 連続気孔多孔体の製造方法
JPH01186303A (ja) * 1988-01-21 1989-07-25 Toyota Motor Corp 鋳込成形法
JPH04270602A (ja) * 1991-02-26 1992-09-28 Ngk Insulators Ltd 高圧鋳込み成形型及びそれを用いた成形方法
JPH05228913A (ja) * 1991-07-26 1993-09-07 Sumitomo Electric Ind Ltd セラミックスの成形法および装置
JPH06285825A (ja) * 1993-04-06 1994-10-11 Denki Kagaku Kogyo Kk 型材及び成形型の製造法
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