Structure for manufacturing cast article

Patent metadata

Field	Value
Publication number	US-12485474-B2
Application number	US-202118035528-A
Country	US
Kind code	B2
Filing date	Oct 4, 2021
Priority date	Nov 9, 2020
Publication date	Dec 2, 2025
Grant date	Dec 2, 2025

Abstract

A structure for manufacturing a cast article includes an organic component, at least a portion thereof being an organic fiber. The structure has a mass reduction rate of 1 mass % or greater to less than 20 mass % when heated under nitrogen atmosphere at 1000° C. for 30 minutes. The cast-article-manufacturing structure includes an inorganic particle. The cast-article-manufacturing structure includes, as the inorganic particle, a first inorganic particle having a predetermined shape and/or physical property, and a second inorganic particle having a predetermined shape and/or physical property different from the first inorganic particle. In addition thereto or instead thereof, the cast-article-manufacturing structure has a maximum bending stress of 9 MPa or greater measured in conformity with JIS K7017, and a bending strain of 0.6% or greater at the maximum bending stress.

First claim

The invention claimed is:

1 . A structure for manufacturing a cast article, the structure comprising:
an organic component; and a plurality of inorganic particles on a surface of the structure, wherein: at least a portion of the organic component is an organic fiber dispersed on the surface of the structure and in an interior of the structure, the structure has a mass reduction rate of greater than 5 mass % to less than 20 mass % when heated under nitrogen atmosphere at 1,000° C. for 30 minutes, the plurality of inorganic particles include a first inorganic particle which is not a layered particle, and a second inorganic particle which is a layered particle, the first inorganic particle has a first melting point of 1,200° C. or higher, and the second inorganic particle having a second melting point below 1,200° C., and the structure has a maximum bending stress of 9 MPa or greater measured in conformity with JIS K7017, and a bending strain of 0.6% or greater at the maximum bending stress.

2 . The structure for manufacturing a cast article according to claim 1 , wherein the first inorganic particle has the first melting point of 1,200° C. or higher and 2,500° C. or lower.

3 . The structure for manufacturing a cast article according to claim 1 , wherein the mass reduction rate is less than 15 mass %.

4 . The structure for manufacturing a cast article according to claim 1 , wherein the maximum bending stress is 9 MPa or greater and 50 MPa or less.

5 . The structure for manufacturing a cast article according to claim 1 , wherein the bending strain at the maximum bending stress is 0.65% or greater and 8% or less.

6 . The structure for manufacturing a cast article according to claim 1 , wherein each of the plurality of inorganic particles is one or two or more types selected from aluminum oxide, silicon dioxide, and iron oxide.

7 . The structure for manufacturing a cast article according to claim 1 , wherein each of the plurality of inorganic particles is one or more types selected from spherical particles and layered particles.

8 . The structure for manufacturing a cast article according to claim 1 , wherein 50 pieces or more and 300 pieces or fewer of the organic fiber are present per 100 mm 2 on the surface of the structure for manufacturing the cast article.

9 . The structure for manufacturing a cast article according to claim 1 , wherein
the organic fiber on the surface of the structure for manufacturing the cast article has an average fiber length of 0.5 mm or greater and 7 mm or less, the organic fiber on the surface of the structure for manufacturing the cast article has an average fiber diameter of less than 40 μm and 8 μm or greater, a content of inorganic fiber included in the structure for manufacturing the cast article is from 0 to 20 mass %, and a content of the organic component in the structure for manufacturing the cast article is from 7.0 to less than 20 mass %.

10 . The structure for manufacturing a cast article according to claim 9 , wherein a ratio of an average fiber length of the organic fiber on the surface of the structure for manufacturing the cast article to the average fiber diameter of the organic fiber present on the surface is 10 or greater and 260 or less.

11 . The structure for manufacturing a cast article according to claim 1 , further comprising another organic component.

12 . The structure for manufacturing a cast article according to claim 1 , wherein the organic fiber includes one or plural selected from pulp fiber, fiber including polyester resin, and fiber including aramid resin.

13 . The structure for manufacturing a cast article according to claim 1 , wherein a content of inorganic fiber included in the structure for manufacturing the cast article is from 0 to 20 mass %.

14 . The structure for manufacturing a cast article according to claim 1 , wherein a content of the organic component in the structure for manufacturing the cast article is from 7.0 to less than 20 mass %.

15 . The structure for manufacturing a cast article according to claim 14 , wherein the content of the organic fiber in the structure for manufacturing the cast article is from 0.3 to 10 mass %.

16 . The structure for manufacturing a cast article according to claim 1 , wherein the structure for manufacturing the cast article has a thickness of 0.2 mm or greater and 10 mm or less.

17 . The structure for manufacturing a cast article according to claim 1 , wherein
each of the plurality of inorganic particles is in the interior of the structure, the first inorganic particle and the second inorganic particle are different from one another in terms of predetermined shape and/or physical properties, the first inorganic particle is spherical, an average particle size of the first inorganic particle is 1 μm or greater and 1,000 μm or less, an average particle size of the second inorganic particle is 0.1 μm or greater and 500 μm or less, a ratio of an average fiber length of the organic fiber on the surface of the structure for manufacturing the cast article to an average fiber diameter of the organic fiber present on the surface is 10 or greater and 260 or less, the maximum bending stress is 9 MPa or greater and 50 MPa or less, and the bending strain at the maximum bending stress is 0.65% or greater and 8% or less.

18 . A method comprising:
providing a structure for manufacturing a cast article, the structure including:
an organic component; and
a plurality of inorganic particles on a surface of the structure, wherein:
at least a portion of the organic component is an organic fiber dispersed on the surface of the structure and in an interior of the structure; the structure has a mass reduction rate of greater than 5 mass % to less than 20 mass % when heated under nitrogen atmosphere at 1,000° C. for 30 minutes; the plurality of inorganic particles include a first inorganic particle which is not a layered particle, and a second inorganic particle which is a layered particle; the first inorganic particle has a first melting point of 1,200° C. or higher, and the second inorganic particle having a second melting point below 1,200° C.; and the structure has a maximum bending stress of 9 MPa or greater measured in conformity with JIS K7017, and a bending strain of 0.6% of greater at the maximum bending stress.

19 . The method according to claim 18 , further comprising manufacturing the cast article using the structure for manufacturing the cast article.

Assignees

• Kao Corp

Inventors

• Mashiko Yuki
• Kibe Yoshiyuki
• Natsui Shohei
• Mori Toshihiko

Classifications

• B22C1/02

  characterised by additives for special purposes, e.g. indicators, breakdown additives · CPC title

• B22C9/082

  Sprues, pouring cups · CPC title

• B22C1/181

  Cements, oxides or clays · CPC title

• B22C1/04 Primary

  for protection of the casting, e.g. against decarbonisation · CPC title

• B22C1/00 Primary

  Compositions of refractory mould or core materials; Grain structures thereof (refractory materials in general C04B35/00); Chemical or physical features in the formation or manufacture of moulds · CPC title