Member for producing castings

• US 7,503,999 B2
• Filed: 11/11/2003
• Issued: 03/17/2009
• Est. Priority Date: 11/13/2002
• Status: Active Grant

• Current Assignee: KAO Corporation
• Original Assignee: KAO Corporation
• Inventors: Kobayashi, Hiroaki, Takagi, Yoshimasa, Tsuura, Tokuo, Nakai, Shigeo, Sono, Tokihito
• Primary Examiner(s): Hug; Eric
• Assistant Examiner(s): CORDRAY, DENNIS R
• Application Number:
  US10/534,798
• Publication Number:
  US 20060130987A1
• Time in Patent Office: 1,953 Days
• Field of Search: 428/34.2, 428/34.5, 428/34.7, 162/118, 162/141, 162/164.1, 162/181.6, 138/154, 164/418, 164/437, 164/349, 164/364
• US Class Current: 162/118
• CPC Class Codes: B22C 9/082 Sprues, pouring cups
• CPC Class Codes: Y10T 428/1303 Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
• CPC Class Codes: Y10T 428/1314 Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/1321 Polymer or resin containing [i.e., natural or synthetic]

Abstract

A part for casting obtained by converting base paper for paper tubing into a tube and containing an organic fiber, an inorganic fiber, and a binder. The part is preferably obtained by winding the base paper into tubing. The part preferably contains 10 to 70 parts by weight of the organic fiber, 1 to 80 parts by weight of the inorganic fiber, 10 to 85 parts by weight of the binder. The organic fiber is preferably pulp fiber.

Claims

1. A part for casting, into which a molten metal is poured, comprising base paper for paper tubing and containing an organic fiber, a carbon fiber for reducing thermal shrinkage, and binder, the base paper being spiral-wound into a tube such that the base paper is wound with an overlap between adjacent turns and a plurality of base papers are wound one on top of another, the total content of carbon fiber being 7 to 80 parts by weight of the base paper, and the total weight of the organic fiber, the carbon fiber, and the binder being taken as 100 parts weight;

wherein the binder comprises an organic binder.

2. The part for casting according to claim 1, comprising 10 to 70 parts by weight of the organic fiber, 7 to 80 parts by weight of the carbon fiber, and at least 10 parts by weight of the binder, the total weight of the organic fiber, the carbon fiber, and the binder being taken as 100 parts by weight.

3. The part for casting according to claim 1, wherein the binder comprises at least two binders having different melting points.

4. The part for casting according to claim 1, wherein the binder consists of an organic binder and an inorganic binder.

5. The part for casting according to claim 4, wherein the inorganic binder is a compound mainly comprising SiO₂.

6. The part for casting according to claim 1, wherein the organic fiber is paper fiber.

7. A method for casting production comprising burying the part for casting according to claim 1 in casting sand.

8. A process of producing a part for casting according to claim 1, comprising the steps of making base paper for paper tubing by papermaking using a slurry containing at least the organic fiber and the carbon fiber, converting the base paper into a spiral-wound paper tube by winding the base paper in a helix pattern such that the base paper is wound with an overlap between adjacent turns and a plurality of base papers are wound one on top of another, and incorporating the binder into the paper tube.

9. The process of producing a part for casting according to claim 8, wherein the step of incorporating the binder into the paper tube is impregnation.

10. The process of producing a part for casting according to claim 9, wherein the slurry further contains an inorganic binder.