| Cast article utilizing mold -> Monitor Keywords |
|
|
  Cast article utilizing moldUSPTO Application #: 20080000607Title: Cast article utilizing mold Abstract: A cast article includes a porous layer having a three-dimensional porous structure, and is manufactured utilizing a mold manufactured by: scattering and adhering combustible powdery particles around a wax mold, which is a lost pattern, to form a layer of combustible powdery particles around the wax mold; coating a film of a ceramic precursor slurry around the wax mold; subjecting the wax mold coated with the slurry film to a heat treatment at 100 to 180° C., to dewax only the wax mold without the combustible powdery particles; and burning and vanishing and firing the slurry film, to burn and vanish the powdery particles in the slurry film and form a shell. Casting the cast article by: pouring a molten metal into the cavity of the mold; cooling the molten metal; and removing the shell of the mold. (end of abstract)
Agent: Mccormick, Paulding & Huber LLP - Hartford, CT, US Inventors: KAZUYOSHI CHIKUGO, HIDEMI UKAI, KOICHI MURAKAMI, KOSHICHI OGAWA USPTO Applicaton #: 20080000607 - Class: 164072000 (USPTO) Related Patent Categories: Metal Founding, Process, Shaping Liquid Metal Against A Forming Surface, Coating Mold Surface With A Treating Agent The Patent Description & Claims data below is from USPTO Patent Application 20080000607. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is entitled to the benefit of International Application No. PCT/JP2004/002708 filed on Mar. 4, 2004, Japanese Patent Application No. 2003-058713 filed on Mar. 5, 2003 and Japanese Patent Application No. 2004-023863 filed on Jan. 30, 2004 and is a Divisional application of U.S. Ser. No. 10/547774, filed on Sep. 1, 2005, now U.S. Pat. No. ______. FIELD OF THE INVENTION [0002] The present invention relates to a cast article manufactured by utilizing a mold. BACKGROUND OF THE INVENTION [0003] In a carrier of a catalyst, or an artificial bone, an artificial dental root (hereinafter, referred to as an implant member) for artificial biomaterial transplantation, a porous layer having a porous structure is formed on the surface in order to increase a surface area. [0004] As a method for forming a porous layer having a porous structure on a surface, the following two methods have been used, that is, (1) a method carrying out a laser beam machining on the surface of a metallic body (or an alloy body), and (2) a method piling up thin sheets made with metallic materials having many pores while three-dimensionally controlling a hole shape in the porous structure, which is described in Japanese Patent Application Laid-Open No. H10-155823. [0005] Incidentally, as for the manufacturing method (1), although the metallic body (or the alloy body) having a porous structure only on the surface, that is, a rough surface, can be easily obtained, there was the problem that a porous layer having a three-dimensional porous structure cannot be obtained. Further, in the case of a metal (or an alloy) having high melting point, there were problems that a high output laser beam machine and a long processing time were necessary for the laser beam machining. [0006] Further, as for the manufacturing method (2), although a porous layer having a three-dimensional porous structure could be formed, there were problems that it took the time and effort for controlling the pore shape and that a long time was necessary for manufacturing. [0007] Thus, it is desired that the above-mentioned porous layer is made by a casting method capable of comparatively easy manufacture. When a porous article is manufactured by the casting method, projections formed on an inner surface of a mold constitute pores of a porous article. However, in order to take out a cast body from the mold, the head of each projection must be narrower than its base. Therefore, as for the pore shape of the porous article obtained by the casting method, a bottom part of the pore is narrower than an opening part of the hole. As a result, for example, one like a golf ball having a concave dimple on the surface could be cast, but there was a problem to make a cast article having a complicated three-dimensional porous structure on the surface by casting. [0008] The present invention solves the above-mentioned problems, and the primary objective is to provide a method for manufacturing a mold, wherein a porous body can be made. DISCLOSURE OF THE INVENTION [0009] One embodiment of the present invention is as follows. That is, a layer of combustible powdery particles is formed around a wax mold, which is a lost pattern. A film of a ceramic precursor slurry is coated around the wax mold having a layer of powdery particles formed thereon. Then, a resultant product is heated to dewax the wax mold, and thereafter, the slurry film is fired to burn and vanish the powdery particles inside the slurry film, and to form a shell. Thereby, the mold having a porous layer on the surface of the cavity of the shell can be made, wherein the porous layer has a three-dimensional porous structure. [0010] Another embodiment of the present invention is as follows. That is, a layer of combustible powdery particles is formed on an inner surface of a female mold for forming a wax mold, which is a lost pattern. A wax material is injected into the female mold, and the wax mold is formed around which has the layer of the powdery particles. Then, a film of a ceramic precursor slurry is coated around the wax mold. Then, after dewaxing the wax mold by heating, the powdery particles inside of the slurry film is burned and vanished by firing the slurry film, and a shell is formed. Thereby, the mold having a porous layer on the surface of the cavity of the shell can be manufactured, wherein the porous layer has a three-dimensional porous structure. [0011] Another embodiment of the present invention is a mold made by any one of the above-described methods for manufacturing the mold, and the mold has a porous layer on the surface of the cavity of a shell, wherein the porous layer has a three-dimensional porous structure. [0012] In addition, another embodiment of the present invention is a method for manufacturing a cast article by the steps of pouring a molten metal into the cavity of a mold obtained by any one of the above-described methods for manufacturing the mold, cooling the molten metal, and removing the shell. Thereby, it is possible to manufacture a cast article having a porous layer at least on the surface thereof, wherein the porous layer has a three-dimensional porous structure. [0013] Furthermore, another embodiment of the present invention is a cast article manufactured by any one of the above-described methods. Thereby, it is possible to manufacture the cast article having a porous layer at least on the surface thereof, wherein the porous layer has a three-dimensional porous structure, and preferably to manufacture an implant member, a catalyst carrier, a turbine rotor, a turbine blade, or the like. BRIEF DESCRIPTION OF DRAWINGS [0014] FIG. 1 is a flow chart showing a casting method of a cast article according to one preferred embodiment of the present invention. [0015] FIG. 2 is a perspective schematic view illustrating one example of a wax mold. [0016] FIG. 3 is a perspective schematic view of a wax mold where a layer of combustible powdery particles is formed around the wax mold shown in FIG. 2. [0017] FIG. 4 is a cross-sectional view taken along the line 4-4 shown in FIG. 3. [0018] FIG. 5 is a cross-sectional view when a film of ceramic precursor slurry is coated around the wax mold shown in FIG. 4. [0019] FIG. 6 is a cross-sectional view of a mold precursor obtained by dewaxing the wax from the coated wax mold shown in FIG. 5. Continue reading... Full patent description for Cast article utilizing mold Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Cast article utilizing mold patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Cast article utilizing mold or other areas of interest. ### Previous Patent Application: Middle layer of die structure that comprises a cavity that holds an alkali metal Next Patent Application: Method of unidirectional solidification of castings and associated apparatus Industry Class: Metal founding ### FreshPatents.com Support Thank you for viewing the Cast article utilizing mold patent info. IP-related news and info Results in 11.01082 seconds Other interesting Feshpatents.com categories: Accenture , Agouron Pharmaceuticals , Amgen , AT&T , Bausch & Lomb , Callaway Golf |
||
