TH80509A - How to create a high-strength casting product - Google Patents

Abstract

DC60 (10/02/54) A method for creating a high strength casting product is provided. How to get started From preparing components that can be cast The components that can be casted will It consists of a fibrous mixture of between 40 and 60 wt% and adhesives between 15 and 45 wt%. The casting cavity is loaded with moldable components up to approximately 90% of the cavity capacity before force is fed. The compressed load in the range of approximately 435 to 870 lb / sq in to the castable component, a fixed distance between 0.1 and 0.5 mm is maintained between the first casting. That determines the boundary of the first casting cavity and the second casting Cast products It is removed from the casting cavity when the castable components are sufficiently hardened. Fig. 5 A method for creating a high strength casting product is provided. How to get started From preparing components that can be cast The components that can be casted will It consists of a fibrous mixture of approximately 40 to 60 wt% and an adhesive between approximately 15 to 45 wt%. The cast cavity is filled with a moldable component in The volume reaches approximately 90% of the cavity capacity before being fed the filling pressure. Compressed in the range of approximately 435 to 870 lb / sq in to a castable component, a predetermined distance between approximately 0.1 to 0.5 mm is maintained. Between the first casting that defines the first casting cavity and the second casting The cast product is removed from the casting cavity when the moldable component is made. To solidify enough

Claims (32)

1. The process of creating cast products involves the following steps: Preparation of the castable component, which consists of approximately 40 to 60 wt% (by weight) of fibrous mixture and approximately 15 to 45 wt% of adhesive; filling the casting cavity to approximately 90% of its capacity; applying a packing pressure of approximately 435 to 870 psi to the castable component; maintaining a predetermined gap of approximately 0.1 to 0.5 mm between the first casting that defines the boundary of the first and second castings; and removing the cast product from the cavity once the castable component has sufficiently hardened. 2. Method for creating the molded product according to claim 1, where pressure is applied for a period between approximately 20 and 60 seconds. 3. Method for creating the cast product according to claim 2, where the first and second castings are maintained at temperatures between approximately 110 and 180 °C. 4. Method for creating the cast product according to claim 3, whereby the first casting is maintained at a temperature approximately 20°C higher than the temperature of the second casting. 5. The method for creating the cast product according to claim 2 also involves increasing the distance between the first and second cast sections once the castable component has solidified to approximately 90%. 6. Method for creating a cast product according to claim 5, where the gap is increased to approximately 10 mm. 7. The method for creating the cast product as per claim 6, which also includes compressing the cast product to the desired thickness. 8. Method for creating the cast product as per claim 7, which also includes rolling the surface of the cast product. 9. The method for creating the cast product according to claim 8 involves compressing the cast product to the desired thickness and rolling the surface of the cast product, which also includes reducing the gap to approximately 0.05 to 0.3 mm. 10. How to create a molded product according to claim 9 where the time gap is reduced by using a time period of approximately 15 to 60 seconds. 11. A method for creating cast products according to claim 1 where the moisture content of the castable components is less than approximately 20%. 12. Method for creating cast products according to claim 11, where the moisture content of the castable components is in the range of approximately 4 to 15%. 13. Method for creating a molded product as per claim 11, where the moisture content of the fibrous components is less than approximately 15%. 14. Method for creating cast products under claim 12 where the castable components will also contain no more than approximately 40 wt% additives. 15. Method for creating the molded product according to claim 14, where the additives are among a group consisting of hardeners, flow promoters, and mold release agents. 16. Method for creating the molded product according to claim 1, where the fibrous mixture consists of multiple fibers, each fiber being up to approximately 50 mm in length. 17. Method for creating a molded product according to claim 16, where each fiber has a thickness of up to approximately 2 mm. 18. Method for creating a molded product according to claim 17, where the fibers have a length-to-thickness ratio ranging from approximately 2:1 to 25:1. 19. Method for fabricating the molded product as per claim 1, where the fibrous mixture contains between approximately 5 and 30 wt% oil palm fiber. 20. Method for constructing the molded product as per claim 1, whereby the fibrous mixture shall consist of one of the following groups: oil palm fiber, brewer's malt, sugarcane pulp, plasticizer, viscous agent, and impact modifier. 21. Method for creating the molded product as described in Patent 1, where the adhesive is a heat-curing resin. 22. Method for creating the molded product as per claim 21, where the adhesive is an amino resin. 23. Method for manufacturing the molded product as per claim 21, where the adhesive still contains melamine. 24. Method for manufacturing the molded product as per claim 23, where the adhesive is one of a group consisting of melamine formaldehyde and melamine urea formaldehyde. 25. The method of creating the castable product according to claim 1, whereby the preparation of the castable component shall consist of weighing each component of the castable component separately and mixing each component of the castable component in a mixer to create a castable component that is adequately coated and homogeneous. 26. The method for creating the castable product under claim 25, whereby the preparation of the castable components shall also involve the mixing of each liquid component of the castable component into a second mixer to create a liquid mixture. 27. The method for creating the cast product under claim 26, whereby the preparation of the castable components shall also involve the injection of a liquid mixture into a mixer. 28. Method for producing the molded product as per claim 27, where the mixer operates at a rotor speed of approximately 29 revolutions per minute. 29. The process of creating cast products involves the following steps: Filling the casting cavity with a fibrous mixture of approximately 40 to 60 wt% and an adhesive of approximately 15 to 45 wt%, filling the cavity to approximately 90% of its capacity; activating the mold to deliver packing pressure between 435 and 870 psi to the castable component; providing a pressure-sensitive vapor vent within the castable component, with controlled vapor volume and pressure to achieve a predetermined density and strength, resulting in a cast product; and finally, removing the cast product from the cavity once the castable component has sufficiently solidified. 30. The method under claim 29, whereby the vapor vent is provided by maintaining the distance between the corresponding parts of the mold adjacent to the castable component. 31. The method under claim 29 whereby the vapor vent is temporarily blocked by a component that can be molded into the mold to prevent the release of moisture vapors for a temporarily specified period. 32. The method under claim 29 in which the amount of moisture vapor is controlled to create vapor bubbles in the castable component, resulting in the production of a cast product with a predetermined porous density.