Cold cast mass element

Abstract

A cold cast mass element has solid metal particles of greater than 75% by volume and a binding agent of less than 25% by volume, with an outside surface. The binding agent is exposed on the outside surface and encapsulates the solid metal particles within the cold cast mass element. The may have an outside surface has a hardness of greater than durometer 70 Shore A and preferably has a hardness of above about 75 Shore A or above about 100 Shore D. The mass element has a binding agent which is an epoxy resin or thermosetting phenol formaldehyde resin. The metal particles can be grinded iron of preferably 85% to 96% by volume with a binding agent 4% to 12% by volume. The mass element preferably has solid metal particles of greater than 85% by weight; and a binding agent of less than 15% by weight.

1 . A cold cast mass element comprising:
 a. solid metal particles of greater than 75% by volume;   b. a binding agent of less than 25% by volume;   c. an outside surface, wherein the binding agent is exposed on the outside surface and encapsulates the solid metal particles within the cold cast mass element, wherein the outside surface has a hardness of greater than durometer 70 Shore A.   
   
   
       2 . The cold cast mass element of  claim 1 , wherein the cold cast mass element outside surface has a hardness of above about 75 Shore A. 
   
   
       3 . The cold cast mass element of  claim 1 , wherein the binding agent is an epoxy resin or thermosetting phenol formaldehyde resin. 
   
   
       4 . The cold cast mass element of  claim 1 , wherein the solid metal particles are grinded iron. 
   
   
       5 . The cold cast mass element of  claim 1 , wherein the solid metal particles are grinded iron of 85% to 96% by volume. 
   
   
       6 . The cold cast mass element of  claim 1 , wherein the binding agent is 4% to 12% by volume. 
   
   
       7 . A cold cast mass element comprising:
 a. solid metal particles of greater than 75% by volume;   b. a binding agent of less than 25% by volume;   c. an outside surface, wherein the binding agent is exposed on the outside surface and encapsulates the solid metal particles within the cold cast mass element, wherein the outside surface has a hardness of greater than durometer above about 100 Shore D.   
   
   
       8 . The cold cast mass element of  claim 7 , wherein the cold cast mass element has a hardness of above about 75 Shore A. 
   
   
       9 . The cold cast mass element of  claim 7 , wherein the binding agent is an epoxy resin or thermosetting phenol formaldehyde resin. 
   
   
       10 . The cold cast mass element of  claim 7 , wherein the solid metal particles are grinded iron. 
   
   
       11 . The cold cast mass element of  claim 7 , wherein the solid metal particles are grinded iron of 85% to 96% by volume. 
   
   
       12 . The cold cast mass element of  claim 7 , wherein the binding agent is 4% to 12% by volume. 
   
   
       13 . A cold cast mass element comprising:
 a. solid metal particles of greater than 85% by weight;   b. a binding agent of less than 15% by weight;   c. an outside surface, wherein the binding agent is exposed on the outside surface and encapsulates the solid metal particles within the cold cast mass element, wherein the outside surface has a hardness of greater than durometer 70 Shore A.   
   
   
       14 . The cold cast mass element of  claim 13 , wherein the cold cast mass element outside surface has a hardness of above about 75 Shore A. 
   
   
       15 .  1 . The cold cast mass element of  claim 13 , wherein the cold cast mass element outside surface has a hardness of above about 75 Shore A. 
   
   
       16 . The cold cast mass element of  claim 13 , wherein the binding agent is an epoxy resin or thermosetting phenol formaldehyde resin. 
   
   
       17 . The cold cast mass element of  claim 13 , wherein the solid metal particles are grinded iron. 
   
   
       18 . The cold cast mass element of  claim 13 , wherein the outside surface has a hardness of greater than durometer above about 100 Shore D.