Mold assembly

• US 4,708,626 A
• Filed: 03/07/1986
• Issued: 11/24/1987
• Est. Priority Date: 03/14/1985
• Status: Expired due to Fees

• Current Assignee: Denki Kagaku Kogyo Kabushiki Kaisha (TDK Corporation)
• Original Assignee: Denki Kagaku Kogyo Kabushiki Kaisha (TDK Corporation)
• Inventors: Sakai, Etsuo, Nishioka, Asaaki, Mino, Iwao, Watanabe, Kiyosi
• Primary Examiner(s): SPITZER, ROBERT H
• Application Number:
  US06/837,449
• Time in Patent Office: 627 Days
• Field of Search: 106/85, 106/97-99, 249/134, 249/135, 425/398, 425/405 H, 425/408, 425/412, 425/416, 425/DIG. 125
• US Class Current: 425/398
• CPC Class Codes: B29C 33/38 characterised by the material or the manufacturing process B29C33/44 takes precedence
• CPC Class Codes: B29C 33/56 Coatings , e.g. enameled or galvanised; Releasing, lubricating or separating agents in-mould coating B29C37/0028; using or applying separating agents B29C37/0067
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2709/06 Concrete
• CPC Class Codes: B29K 2821/00 Use of unspecified rubbers as mould material
• CPC Class Codes: B29K 2863/00 Use of EP, i.e. epoxy resins or derivatives thereof as mould material
• CPC Class Codes: B29K 2909/02 Ceramics
• CPC Class Codes: B29K 2909/06 Concrete
• CPC Class Codes: C04B 14/041 Aluminium silicates other than clay
• CPC Class Codes: C04B 14/043 Alkaline-earth metal silicates, e.g. wollastonite
• CPC Class Codes: C04B 14/064 Silica aerogel
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/305 Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/20 : Retarders
• CPC Class Codes: C04B 2103/302 : Water reducers
• CPC Class Codes: C04B 2111/00939 : for the fabrication of moulds or cores
• CPC Class Codes: C04B 22/064 : of the alkaline-earth metals
• CPC Class Codes: C04B 22/143 : Calcium-sulfate
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 7/02 : Portland cement
• CPC Class Codes: C04B 7/32 : Aluminous cements
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

According to the invention, a mold assembly for molding an article is provided. The mold assembly is composed of at least male and female molds. At least one of the male and female molds is made of a hydraulic material composition having high strength containing a hydraulic material as a main ingredient. A molding face of at least one of the male and female molds is made of a substance other than the hydraulic material.

Claims

1. A mold assembly for molding an article, comprising a male mold and a female mold, said male mold being made of a hydraulic material composition having high strength containing a hydraulic material as a main ingredient, said female mold being made of a substance other than said hydraulic material selected from the group consisting of fluids and rubber-like elastic materials, said male mold being thrust into said female mold so as to deform the female mold.

2. The mold assembly according to claim 1, wherein said hydraulic material composition comprises a hydraulic material, an ultra-fine component, a water reducing agent and water.

3. The mold assembly according to claim 2, wherein said hydraulic material is selected from the group consisting of cements, mineral materials, combinations of materials having hydraulic activities and activators and mixtures thereof.

4. The mold assembly according to claim 3, wherein said cement is selected from the group consisting of Portland cements, oil well cements, blended cements and mixtures thereof.

5. The mold assembly according to claim 3, wherein said mineral material is selected from the group consisting of mineral materials of Ca₃ SiO₅, solid solutions of Ca₃ SiO₅ and mixtures thereof.

6. The mold assembly according to claim 3, wherein said material having hydraulic activity is selected from the group consisting of blast furnace slag, fly ash and mixtures thereof, and said activator is selected from the group consisting of cements, calcium hydroxide, calcium oxide, quick lime, calcium sulfoaluminate minerals, inorganic and organic alkaline salts, calcium sulfate and mixtures thereof.

7. The mold assembly according to claim 3, wherein said activator is selected from the group consisting of calcium hydroxide, calcium oxide, quick lime, cements, and mixtures thereof.

8. The mold assembly according to claim 2, wherein said hydraulic material further contains an additive selected from the group consisting of expansive additives, rapid hardening agents, mixing additives for exhibiting high strength, accelerators, retarders, and mixtures thereof.

9. The mold assembly according to claim 2, wherein said ultra-fine particle component is selected from the group consisting of silica dust, siliceous dust, calcium carbonate, silica gel, opalic silica, fly ash, blast furnace slag, titanium oxide, aluminum oxide, mineral materials of Ca₃ SiO₅, solid solutions of Ca₃ SiO₅ and mixtures thereof.

10. The mold assembly according to claim 2, wherein said ultra-fine particle component has an average particle size of not more than 3 μ

m.

11. The mold assembly according to claim 2, wherein said water reducing agent is selected from the group consisting of those containing, as the main ingredients, salts of condensation product of naphthalenesulfonic acid and formaldehyde, salts of condensation product of alkylnaphthalenesulfonic acid and formaldehyde, salts of condensation product of melaminesulfonic acid and formaldehyde, high molecular weight ligninsulfonate, polycarboxylates, and mixtures thereof.

12. The mold assembly according to claim 2, wherein said hydraulic material composition further includes an aggegate.

13. The mold assembly according to claim 12, wherein said aggregate has a Moh'"'"'s hardness of not less than 6.

14. The mold assembly according to claim 12, wherein said aggregate has a Knoop indentor hardness of not less than 700 kg/mm².

15. The mold assembly according to claim 12, wherein said aggregate is a metallic material.

16. The mold according to claim 1, wherein said fluid is one or more selected from the group consisting of water, oils and air.

17. The mold assembly according to claim 1, wherein said rubber-like elastic material is an urethane rubber.

18. The mold assembly according to claim 1, wherein a fitting member made of a material adapted to be easily machined is provided with said mold assembly at a position for engaging with a molding machine.

19. A mold assembly for molding an article, comprising a male mold and a female mold, one of said male and female molds being made of a hydraulic material composition have high strength containing a hydraulic material as a main ingredient, the other of said male and female molds being made of a substance other than said hydraulic material selected from the group consisting of metallic materials, resins and ceramics.

20. The mold assembly according to claim 19, wherein said hydraulic material composition comprises a hydraulic material, an ultra-fine particle component, a water reducing agent and water.

21. The mold assembly according to claim 20, wherein said hydraulic material is selected from the group consisting of cements, mineral materials, combinations of materials having hydraulic activities and activators and mixtures thereof.

22. The mold assembly according to claim 21, wherein said cement is selected from the group consisting of Portland cements, oil well cements, blended cements and mixtures thereof.

23. The mold assembly according to claim 21, wherein said mineral material is selected from the group consisting of mineral materials of Ca₃ SiO₅, solid solutions of Ca₃ SiO₅ and mixtures thereof.

24. The mold assembly according to claim 21, wherein said material having hydraulic activity is selected from the group consisting of blast furnace slag, fly ash and mixtures thereof, and said activator is selected from the group consisting of cements, calcium hydroxide, calcium oxide, quick lime, calcium sulfoaluminate minerals, inorganic and organic alkaline salts, calcium sulfate and mixtures thereof.

25. The mold assembly according to claim 24, wherein said activator is selected from the group consisting of calcium hydroxide, calcium oxide, quick lime, cements, and mixtures thereof.

26. The mold assembly according to claim 20, wherein said hydraulic material further contains an additive selected from the group consisting of expansive additives, rapid hardening agents, mixing additives for exhibiting high strength, accelerators, retarders, and mixtures thereof.

27. The mold assembly according to claim 20, wherein said ultra-fine particle component is selected from the group consisting of silica dust, siliceous dust, calcium carbonate, silica gel, opalic silica, fly ash, blast furnace slag, titanium oxide, aluminum oxide, mineral materials of Ca₃ SiO₅, solid solutions of Ca₃ SiO₅ and mixtures thereof.

28. The mold assembly according to claim 20, wherein said ultra-fine particle component has an average particle size of not more than 3 μ

m.

29. The mold assembly according to claim 20, wherein said water reducing agent is selected from the group consisting of those containing, as the main ingredients, salts of condensation product of naphthalenesulfonic acid and formaldehyde, salts of condensation product of alkylnaphthalenesulfonic acid and formaldehyde, salts of condensation product of melaminesulfonic acid and formaldehyde, high molecular weight ligninsulfonate, polycarboxylates, and mixtures thereof.

30. The mold assembly according to claim 20, wherein said hydraulic material composition further includes an aggegate.

31. The mold assembly according to claim 30, wherein said aggregate has a Moh'"'"'s hardness of not less than 6.

32. The mold assembly according to claim 30, wherein said aggregate has a Knoop indentor hardness of not less than 700 kg/mm².

33. The mold assembly according to claim 30, wherein said aggregate is a metallic material.

34. The mold assembly according to claim 19, wherein said male mold is made of the hydraulic material composition having high strength, and wherein said female mold is made of a metallic material.

35. The mold assembly according to claim 19, wherein a fitting member made of a material adapted to be easily machined is provided with said mold assembly at a position for engaging with a molding machine.

36. The mold assembly according to claim 19, wherein said article is made of a material selected from the group consisting of metal plates, resins formed by a reaction injection molding process, resins formed by an injection molding process, resins formed by a blow molding process, resins formed by a vacuum molding process, and mixtures of fibers and synthetic resins.

37. A mold assembly for molding an article, comprising a male mold and a female mold, at least one of said male and female molds being made of a hydraulic material composition having high strength containing a hydraulic material as a main ingredient, a molding face of at least one of said male and female molds being made of metal formed by a non-electrolysis plating method.

38. The mold assembly according to claim 37, wherein said hydraulic material composition comprises a hydraulic material, an ultra-fine particle component, a water reducing agent and water.

39. The mold assembly according to claim 38, wherein said hydraulic material is selected from the group consisting of cements, mineral materials, combinations of materials having hydraulic activities and activators and mixtures thereof.

40. The mold assembly according to claim 39, wherein said cement is selected from the group consisting of Portland cements, oil well cements, blended cements and mixtures thereof.

41. The mold assembly according to claim 39, wherein said mineral material is selected from the group consisting of mineral materials of Ca₃ SiO₅, solid solutions of Ca₃ SiO₅ and mixtures thereof.

42. The mold assembly according to claim 39, wherein said material having hydraulic activity is selected from the group consisting of blast furnace slag, fly ash and mixtures thereof, and said activator is selected from the group consisting of cements, calcium hydroxide, calcium oxide, quick lime, calcium sulfoaluminate minerals, inorganic and organic alkaline salts, calcium sulfate and mixtures thereof.

43. The mold assembly according to claim 42, wherein said activator is selected from the group consisting of calcium hydroxide, calcium oxide, quick lime, cements, and mixtures thereof.

44. The mold assembly according to claim 38, wherein said hydraulic material further contains an additive selected from the group consisting of expansive additives, rapid hardening agents, mixing additives for exhibiting high strength, accelerators, retarders, and mixtures thereof.

45. The mold assembly according to claim 38, wherein said ultra-fine particle component is selected from the group consisting of silica dust, siliceous dust, calcium carbonate, silica gel, opalic silica, fly ash, blast furnace slag, titanium oxide, aluminum oxide, mineral materials of Ca₃ SiO₅, solid solutions of Ca₃ SiO₅ and mixtures thereof.

46. The mold assembly according to claim 38, wherein said ultra-fine particle component has an average particle size of not more than 3 μ

m.

47. The mold assembly according to claim 38, wherein said water reducing agent is selected from the group consisting of those containing, as the main ingredients, salts of condensation product of naphthalenesulfonic acid and formaldehyde, salts of condensation product of alkylnaphthalenesulfonic acid and formaldehyde, salts of condensation product of melaminesulfonic acid and formaldehyde, high molecular weight ligninsulfonate, polycarboxylates, and mixtures thereof.

49. The mold assembly according to claim 38, wherein said aggregate has a Moh'"'"'s hardness of not less than 6.

52. The mold assembly according to claim 37, wherein said male mold is made of the hydraulic material composition having high strength, and wherein said female mold is made of a metallic material.

53. The mold assembly according to claim 37, wherein said male and female molds are made of the hydraulic material composition having high strength, and wherein said molding faces are made of a metallic material.

54. The mold assembly according to claim 37, wherein a fitting member made of a material adapted to be easily machined is provided with said mold assembly at a position for engaging with a molding machine.

55. The mold assembly according to claim 37, wherein said plated molding face is prepared by allowing said hydraulic material composition containing calcium to contact with a catalyst solution to deposit and catalyst to form a coating under the action of said calcium and then forming a plated membrane by a non-electrolysis plating method.

56. The mold assembly according to claim 55, wherein said catalyst solution is a weakly acidic solution of a compound of platinum group metal.

57. The mold assembly according to claim 55, wherein said plated molding face is provided over a surface of said hydraulic material composition having high strength and having a porosity of not more than 30%.

58. The mold assembly according to claim 37, wherein said article is made of a material selected from the group consisting of metal plates, resins formed by a reaction injection molding process, resins formed by an injection molding process, resins formed by a blow molding process, resins formed by a vacuum molding process, and mixtures of fibers and synthetic resins.

48. The mold assembly according to claim 48, wherein said hydraulic material composition further includes an aggegate.

50. The mold assembly according to claim 48, wherein said aggregate has a Knoop indentor hardness of not less than 700 kg/mm².

51. The mold assembly according to claim 48, wherein said aggregate is a metallic material.