US 8,034,265 B2 · Dry mixture of an aggregate material, a molding process using the same, and a core mold

Abstract

There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.

Claims18

Dependent claims

A molding process for molding a mold using a dry mixture of an aggregate material prepared by the steps of:

mixing aggregate materials, one or more kind of a water-soluble binder that is soluble by water at ambient temperatures, and water, to make a mixture;
and
evaporating the moisture within said mixture during said mixing step such that said mixture is dried and has single-grain structures;
and
wherein additional water is added to said dry mixture to form a molding material for molding a mold with said dry mixture,
wherein said additional water has a normal temperature, and wherein said dry mixture has an ambient temperature, said process comprising the steps of:
freezing said dry mixture with said additional water such that said single-grain structures in the mixture are maintained;
charging said frozen mixture into a molding space;
evaporating the moisture within said charged mixture to cure said charged mixture to mold a mold with said cured mixture;
and
removing said molded mold from said molding space.

8 more elements

A molding process for molding a mold using a dry mixture of an aggregate material prepared by the steps of:

mixing aggregate materials, one or more kind of a water-soluble binder that is soluble by water at ambient temperatures, and water, to make a mixture;
and
evaporating the moisture within said mixture during said mixing step such that said mixture is dried and has single-grain structures;
and
wherein additional water is added to said dry mixture to form a molding material for molding a mold with said dry mixture,
wherein said additional water has a normal temperature, and wherein said dry mixture has an ambient temperature, said process comprising the steps of:
freezing said mixture with said additional water such that said mixture has single-grain structures;
adding a lubricant to said frozen mixture;
charging said frozen mixture with said lubricant into a molding space;
evaporating the moisture within said charged mixture to cure said charged mixture to mold a mold with said cured mixture;
and
removing said molded mold from said molding space.

9 more elements

A molding process for molding a mold, said process comprising the steps of:

freezing a dry mixture of an aggregate material prepared by the steps of:
mixing an aggregate granular material, a water-soluble binder that is soluble by water at an ambient temperature, a cross-linker that is capable of cross-linking with said water-soluble binder, and water;
evaporating the moisture within said mixture during said mixing step to prevent the cross-linking reaction between said water-soluble binder and said cross-linker such that said mixture is dried and has single-grain structures;
adding additional water to said dry mixture;
freezing said dry mixture with the additional water to maintain said single-grain structures in said mixture in order to form a molding material for molding a mold with said dry mixture;
charging said frozen mixture into a molding space;
evaporating the moisture within said charged mixture to cure said charged mixture to mold a mold with said cured mixture;
causing a cross-linking reaction between said water-soluble binder and said cross-linker;
and
removing said molded mold from said molding space.

7 more elements

A molding process for molding a mold, said process comprising the steps of:

freezing a dry mixture of an aggregate material prepared by the steps of:
mixing an aggregate granular material, a water-soluble binder that is soluble by water at an ambient temperature, a cross-linker that is capable of cross-linking with said water-soluble binder, and water;
evaporating the moisture within said mixture during said mixing step to prevent the cross-linking reaction between said water-soluble binder and said cross-linker such that said mixture is dried and has single-grain structures;
adding additional water to said dry mixture;
freezing said dry mixture with the additional water to maintain said single-grain structures in said mixture in order to form a molding material for molding a mold with said dry mixture
charging said frozen mixture into a molding space;
evaporating the moisture within said charged mixture to cure said charged mixture to mold a mold with said cured mixture;
removing said molded mold from said molding space;
and
causing a cross-linking reaction between said water-soluble binder and said cross-linker.

7 more elements

A molding process for molding a mold, said process comprising the steps of:

freezing a mixture of an aggregate material prepared by the steps of:
mixing an aggregate granular material, a water-soluble binder that is soluble by water at an ambient temperature, a cross-linker that is capable of cross-linking with said water-soluble binder, and water;
evaporating the moisture within said mixture during said mixing step to prevent the cross-linking reaction between said water-soluble binder and said cross-linker such that said mixture is dried and has single-grain structures;
adding additional water to said dry mixture;
freezing said dry mixture with the additional water to maintain said single-grain structures in said mixture in order to form a molding material for molding a mold with said dry mixture;
adding a lubricant to said mixture;
charging said frozen mixture with said lubricant into a molding space;
evaporating the moisture within said charged mixture to cure said charged mixture to mold a mold with said cured mixture;
causing a cross-linking reaction between said water-soluble binder and said cross-linker;
and
removing said molded mold from said molding space.

8 more elements

A molding process for molding a mold, said process comprising the steps of:

freezing a mixture of an aggregate material prepared by the steps of:
mixing an aggregate granular material, a water-soluble binder that is soluble by water at an ambient temperature, a cross-linker that is capable of cross-linking with said water-soluble binder, and water;
evaporating the moisture within said mixture during said mixing step to prevent the cross-linking reaction between said water-soluble binder and said cross-linker such that said mixture is dried and has single-grain structures;
adding additional water to said dry mixture;
freezing said dry mixture with the additional water to maintain said single-grain structures in said mixture in order to form a molding material for molding a mold with said dry mixture;
adding a lubricant to said mixture;
charging said frozen mixture with said lubricant into a molding space;
evaporating the moisture within said charged mixture to cure said charged mixture to mold a mold with said cured mixture;
removing said molded mold from said molding space;
and
causing a cross-linking reaction between said water-soluble binder and said cross-linker.

8 more elements

Dependencies are inferred from the claim text.

Dry mixture of an aggregate material, a molding process using the same, and a core mold

Life of this patent

Dry mixture of an aggregate material, a molding process using the same, and a core mold

Life of this patent

Abstract

Claims18