US3860476A Expired / Lapsed US ⏱️ 0.0 years remaining

Method of forming refractory laminates

Assignee: EIDP Inc

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Filing: 1973-05-07

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Granted: 1975-01-14

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Expires: 1993-05-07

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Abstract

Abstract A rapid process for forming a refractory laminate on the surface of a support structure which comprises dipping the structure in a bath comprising a sol of negatively charged colloidal particles of an inorganic substance and/or a solution of an alkaline ionic silicate to form a layer on the surface, contacting the layer on the surface with refractory stucco grains containing a setting agent to firmly set the colloidal silica or silicate and the stucco grains. This procedure is repeated until a laminate of the desired thickness is built up on the surface. Interaction between the negatively charged colloidal particles or silicate and the stucco grain-setting agent mixture results in the polymerization of the silica or silicate and thereby the immobilization of the coatings. This technique makes it possible to successively apply and set coatings to build refractory laminates in very short times without intermediate drying and without sloughing of coats. The process is particularly suited for making expendable, refractory shell molds for precision investment casting of metals by the so-called ''''lost-wax'''' technique.

Inventors

👤 Jr Earl P Moore

Bibliographic Details

Application Number —

Jurisdiction US

Data Source google_patents

Last Synchronized 2026-10-30 11:54

CPC Classifications

C; C04; C04B; C04B28/00; C04B28/24; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/6303; C04B35/6316; C04B35/632; C04B35/66; C04B2103/00; C04B2103/0004; C04B2103/0021; C04B2111/00; C04B2111/00474; C04B2111/00612; C04B2111/00939; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/34; C04B2235/3418; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1089; Y10T428/00; Y10T428/25; Y10T428/259

Claims Analysis

Total Claims: 9

Claim 1

Independent Claim 26 words

Process of claim 1 wherein the bath of step (a) is a slurry of particulate refractory material in a sol of negatively charged colloidal silica particles.

Claim 2

Dependent Claim 217 words

A rapid process for forming expendable, refractory shell molds for precision investment casting of metals comprising: a. dipping a disposable pattern of the metal casting in a bath comprising at least one member of the group consisting of a sol of negatively charged colloidal particles selected from the group consisting of silica, bentonite, attapulgite and kaolinite; and a basic solution of alkaline ionic silicate to form a layer on the pattern, b. contacting the layer on the surface with refractory stucco grains containing a setting agent to firmly set the layer, the setting agent being selected from the group consisting of monofunctional cationic organic compounds having at least one and no more than two alkyl chains of from 6 to 25 carbon atoms, polycationic organic monomers having from 1 to 24 carbon atoms per functional group, polycationic organic polymers having from 1 to 24 carbon atoms per functional group, positively charged colloidal particles selected from the group consisting of alumina and a silica core coated with a metal-oxygen compound and basic aluminum salts having the general formula Alx(OH)yAz wherein x 1 - 8, y 1 - 20, z 1 - 4 and A is an acid anion, c. repeating steps (a) and (b) in sequence as required to build a refractory shell mold of the desired thickness.

Claim 3

Dependent Claim 25 words

Process of cLaim 3 wherein the bath of step (a) is a slurry of refractory grain in a sol of negatively charged colloidal silica particles.

Claim 4

Dependent Claim 28 words

Process of claim 3 wherein in step (b) the layer on the pattern is contacted with a fluidized bed of refractory stucco grains coated with a setting agent.

Claim 5

Dependent Claim 50 words

Process of claim 4 wherein two slurries of refractory grain in a sol of negatively charged silica particles are used, the first slurry containing relatively fine refractory grain and being used for the prime coat, and the second slurry containing relatively coarse refractory grain and being used for subsequent coats.

Claim 6

Dependent Claim 87 words

Process of claim 6 wherein the setting agent is selected from the group consisting of monofunctional cationic organic compounds having at least one but no more than two alkyl chains of 8 to 20 carbon atoms, polycationic organic monomers having from one to 10 carbon atoms per functional group, polycationic organic polymers having from one to 10 carbon atoms per functional group, and basic aluminum salts having the formula Alx(OH)yAz wherein x 1-2, y 1 - 5, z 1 - 2 and A is an acid anion.

Claim 7

Dependent Claim 27 words

The process of claim 6 wherein the setting agent is a member of the group consisting of basic aluminum chloride, basic aluminum formate and basic aluminum acetate.

Claim 8

Dependent Claim 22 words

The process of claim 6 wherein the refractory stucco grain is coated with from 1 to 30% by weight with setting agent.

Claim 9

Dependent Claim 22 words

The process of claim 6 wherein the refractory stucco grain is coated with from 3 to 15% by weight with setting agent.

References Cited (Backward Citations)

US3270382A Cited

US3292220A Cited

US3226784A Cited

US3428465A Cited

US3748157A Cited

US3751276A Cited

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USPTO Annuity & Maintenance Windows

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1978-01-13	1978-07-15	1979-01-14	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1982-01-13	1982-07-15	1983-01-14	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1986-01-13	1986-07-15	1987-01-14	$7700.00	Window Closed / Lapsed

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