Binder coated refractories, casting mold using the same, and method of manufacturing casting mold using the same

Abstract

The binder coated refractories comprises the refractory aggregates and the solid-form coating layer which comprises the sugar group as the binder and which is provided to the surface of the refractory aggregates. According to this, the sugar group is used as the binder for bonding the refractory aggregates. Further, even if the sugar group is thermally decomposed, the sugar group emits the carbon dioxide and the water. Therefore, there is little likelihood of emitting the harmful gas. Therefore, it is possible to reduce the environmental pollution. Further, the sugar group is thermally decomposed easily. Therefore, it is possible to manufacture the casting mold having the good breaking property.

1 . Binder coated refractories each comprising:
 a refractory aggregate,   wherein   each of said refractory aggregate is coated with a coating layer which has a sugar group defined as a binder and which is a solid form.   
     
     
         2 . The binder coated refractories a set forth in  claim 1 , wherein
 said coating layer has the binder which comprises the sugar group in addition to a thermosetting resin.   
     
     
         3 . The binder coated refractories as set forth in  claim 2 , wherein
 said thermosetting resin is a phenolic resin.   
     
     
         4 . The binder coated refractories as set forth in  claim 1 , wherein
 said coating layer further comprises a carboxylic acid as a curing agent of the sugar group.   
     
     
         5 . The binder coated refractories as set forth in  claim 1 , wherein
 said refractory aggregates are selected from at least one of silica sand, pit sand, alumina sand, olivine sand, chromite sand, zircon sand, mullite sand, and artificial sand.   
     
     
         6 . The binder coated refractories as set forth in  claim 2 , wherein
 said thermosetting resin is configured to coat a surface of each said refractory aggregate, and   said sugar group is configured to coat a surface of each said thermosetting resin.   
     
     
         7 . The binder coated refractories as set forth in  claim 1 , wherein
 a proportion of the binder in the refractory aggregates is from 0.5 percents by mass or more to 5 percents by mass or less.   
     
     
         8 . The binder coated refractories as set forth in  claim 2 , wherein
 a proportion of said thermosetting resin in a total amount of said binder is more than 0 percents by mass and 80 percents by mass or less.   
     
     
         9 . The binder coated refractories as set forth in  claim 8 , wherein
 a proportion of said thermosetting resin in a total amount of said binder is more than 0 percents by mass and 50 percents by mass or less.   
     
     
         10 . The binder coated refractories as set forth in  claim 1 , wherein
 said sugar group is located in an outermost of said coating layer.   
     
     
         11 . A casting mold comprising said binder coated refractories as set forth in  claim 1 , wherein
 said binder coated refractories are bonded to each other with the binder in the coating layer.   
     
     
         12 . A method of manufacturing a casting mold using the binder coated refractories as set forth in  claim 1 , said method comprises:
 a step of filling a mixture of the binder coated refractories and the water in a casting flask, and   a step of freezing the water in the mixture.   
     
     
         13 . The method of manufacturing a casting mold using binder coated refractories each comprising a refractory aggregate and a coating layer, each said refractory aggregate having fire resistance, each said coating layer being configured to coat a surface of each the refractory aggregates, said coating layer having a binder which has a sugar group, each said coating layer having a solid form,
 said method comprising:   a filling step of filling the binder coated refractories in a casting flask;   a solidifying-hardening step of
 supplying water vapor to an inside of said casting flask to change said sugar groups into said sugar groups having sticky paste condition, 
 then, heating said binder coated refractories to solidify-harden said binders in said coating layers, whereby said binder coated refractories are bonded with each other. 
   
     
     
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         22 . The method of manufacturing the casting mold as set forth in  claim 13 , wherein
 said water vapor is a saturated water vapor,   said method comprising steps of:
 supplying moisture into the casting flask filled with said binder coated refractories to provide wet to the binder, 
 then, supplying the superheated steam into the casting flask to heat the binder coated refractories and to remove the moisture of said binder and increase the temperature of the binder coated refractories by the latent heat of the condensation of the superheated steam, whereby the binders of the coating layers are solidified-hardened and the binder coated refractories are bonded with each other. 
   
     
     
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         30 . A method of manufacturing a casting mold using binder coated refractories which comprises refractory aggregates and coating layers, said refractory aggregates having fire resistance, each said coating layer coating a surface of each said refractory aggregate, each said coating layer comprising a binder having a sugar group, each said coating layer having a solid form, said method comprising:
 a filling step of filling said binder coated refractories to a casting flask,   a solidifying-hardening step of
 supplying moisture into the casting flask to provide a wet to said binder and to provide said sugar group with sticky paste condition, 
 then, supplying a superheated steam into said casting flask cause increasing of the temperature of said binder coated refractories, 
 drying said binder coated refractories and solidifying-hardening said binder of said coating layer by increasing the temperature of said binder coated refractories to bond said binder coated refractories with each other.