US3929685A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for producing casting molds suitable for use in the ceramic industry
Assignee: Individual
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Filing: 1973-06-11
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Granted: 1975-12-30
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Expires: 1993-06-11
Abstract
Abstract A process for producing casting molds suitable for use in the ceramic industry and consisting of a polymerized material having minute, open pores and possessing a high degree of mechanical strength and an excellent water permeability. There is formed a castable mixture comprising A. a major amount of a polymer powder composed of spherical particles and having a polymerization catalyst uniformly distributed over the entire surface of said particles, B. an emulsion of at most about 20% by weight of water, based on said mixture; at least one water-insoluble, liquid monomeric or only partially polymerized compound polymerizable to form a rigid polymer and capable of being slightly imbibed by said polymer powder, as the oil phase; and a surface active agent capable of maintaining said emulsion; and optionally C. an accelerator for the polymerization of said polymerizable compound. Said mixture is cast to form a casting mold or a filter for liquid or gaseous media or the like, and then polymerized. Finally, the water can be removed from the pores.
Inventors
- 👤 Bruno Jung
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 03:52
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/28; C08J9/283; B; B28; B28B; B28B1/00; B28B1/26; B28B1/261; B28B1/262; B28B1/263
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
156 words
A PROCESS FOR PRODUCING CASTING MOLDS SUITABLE FOR USE IN THE CERAMIC INDUSTRY, SAID PROCESS COMPRISING THE STEPS OF: A. FORMING A CASTABLE MIXTURE OF AN EMULSION AND A MAJOR AMOUNT OF AT LEAST ONE POLYMER COMPONENT, B. SAID POLYMER COMPONENT BEING IN THE FORM OF A POWDER COMPOSED OF SPHERICAL PARTICLES AND HAVING A POLYMERIZATION CATALYST UNIFORMLY DISTRIBUTED OVER THE ENTIRE SURFACE OF SAID PRRTICLES, C. SAID EMULSION COMPRISING AT MOST 20% BY WEIGHT OF WATER BASED ON SAID CATABLE MIXTURE, A SURFACE ACTIVE AGENT CAPABLE OF MAINTAINING SAID EMULSION, AND A POLYMERIZABLE COMPOUND COMPRISING AT LEAST ONE WATER INSOLUBLE LIQUID MONOMERIC OR ONLY PARTIALLY POLYMERIZED COMPOUND POLYMERIZABLE TO FORM A RIGID POLYMER AND CAPABLE OF BEING SLIGHTLY IMBIBED BY SAID POLYMER POWDER AS THE OIL PHASE, D. CASTING SAID CASTABLE MIXTURE TO FORM A CASTING MOLD, E. POLYMERIZING SAID POLYMERIZABLE COMPOUND, AND F. REMOVING THE WATER FROM THE PORES OF THE MOLD THUS PRODUCED.
Claim 2
Dependent Claim
156 words
A PROCESS FOR PRODUCING CASTING MOLDS SUITABLE FOR USE IN THE CERAMIC INDUSTRY, SAID PROCESS COMPRISING THE STEPS OF: A. FORMING A CASTABLE MIXTURE OF AN EMULSION AND A MAJOR AMOUNT OF AT LEAST ONE POLYMER COMPONENT, B. SAID POLYMER COMPONENT BEING IN THE FORM OF A POWDER COMPOSED OF SPHERICAL PARTICLES AND HAVING A POLYMERIZATION CATALYST UNIFORMLY DISTRIBUTED OVER THE ENTIRE SURFACE OF SAID PRRTICLES, C. SAID EMULSION COMPRISING AT MOST 20% BY WEIGHT OF WATER BASED ON SAID CATABLE MIXTURE, A SURFACE ACTIVE AGENT CAPABLE OF MAINTAINING SAID EMULSION, AND A POLYMERIZABLE COMPOUND COMPRISING AT LEAST ONE WATER INSOLUBLE LIQUID MONOMERIC OR ONLY PARTIALLY POLYMERIZED COMPOUND POLYMERIZABLE TO FORM A RIGID POLYMER AND CAPABLE OF BEING SLIGHTLY IMBIBED BY SAID POLYMER POWDER AS THE OIL PHASE, D. CASTING SAID CASTABLE MIXTURE TO FORM A CASTING MOLD, E. POLYMERIZING SAID POLYMERIZABLE COMPOUND, AND F. REMOVING THE WATER FROM THE PORES OF THE MOLD THUS PRODUCED.
Claim 3
Dependent Claim
20 words
The process as defined in claim 1 wherein said emulsion includes an accelerator for the polymerization of said polymerizable compound.
Claim 4
Dependent Claim
58 words
A process as defined in claim 2 wherein the castable mixture consists essentially of 100 to 150 parts by weight of said polymer powder, 5 to 50 parts by weight of water provided that said water does not comprise more than 20% by weight of said castable mixture, 5 to 60 parts by weight of said polymerizable compound.
Claim 5
Dependent Claim
37 words
A process as defined in claim 1 wherein said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof.
Claim 6
Dependent Claim
27 words
A process as defined in claim 1 wherein said polymerizable compound is selected from the group consisting of esters of methacrylic and acrylic acid and mixtures thereof.
Claim 7
Dependent Claim
15 words
A process as defined in claim 1 wherein said polymerizable material consists essentially of styrene.
Claim 8
Dependent Claim
20 words
A process as defined in claim 1 wherein said polymerizable compound consists essentially of an unsaturated polyester dissolved in styrene.
Claim 9
Dependent Claim
25 words
A process as defined in claim 1 wherein about 80% by weight of said polymer powder has an average particle size finer than 200 microns.
Claim 10
Dependent Claim
22 words
A process as defined in claim 1 wherein the polymer components consist of two or more fractions having different average particle sizes.
Claim 11
Dependent Claim
56 words
A process as defined in claim 1 wherein said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof, said polymerizable compound is selected from the group consisting of esters of methacrylic and acrylic acid and mixtures thereof.
Claim 12
Dependent Claim
44 words
A process as defined in claim 1 wherein said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof, said polymerizable material consists essentially of styrene.
Claim 13
Dependent Claim
49 words
A process as defined in claim 1 wherein said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof, said polymerizable compound consists essentially of an unsaturated polyester dissolved in styrene.
Claim 14
Dependent Claim
54 words
A process as defined in claim 1 wherein said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof, about 80% by weight of said polymer powder has an average particle size finer than 200 microns.
Claim 15
Dependent Claim
51 words
A process as defined in claim 1 wherein said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof, the polymer components consist of two or more fractions having different average particle sizes.
Claim 16
Dependent Claim
87 words
A process as defined in claim 1 wherein the castable mixture consists essentially of 100 to 150 parts by weight of said polymer powder, 5 to 50 parts by weight of water provided that said water does not comprise more than 20% by weight of said castable mixture, 5 to 60 parts by weight of said polymerizable compound, said polymer powder is selected from the group consisting of poly(methyl methacrylate), poly(butyl methacrylate), poly(ethyl methacrylate), copolymers of acrylic and methacrylic acid and the esters thereof, and mixtures thereof.
Claim 17
Dependent Claim
25 words
A process as defined in claim 15 wherein about 80% by weight of said polymer powder has an average particle size finer than 200 microns.
Claim 18
Dependent Claim
22 words
A process as defined in claim 15 wherein the polymer components consist of two or more fractions having different average particle sizes.
Claim 19
Dependent Claim
45 words
A process as defined in claim 1 wherein said polymerizing step is effective to produce a solid plastic material casting having open pores with a density of 0.8 to 1.00 grams/cc, a uniform pore structure and a pore volume of about 10 to about 30%.
Claim 20
Dependent Claim
65 words
A process as defined in claim 1 wherein said polymerizing step is effective to produce a solid plastic material casting having open pores with a density of 0.8 to 1.00 grams/cc, about 30% open pores, an average pore size of 1 to 20 microns, a tensile strength of about 60 to about 150 kp/cm2 and a compression strength of about 300 to about 450 kp/cm2.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-12-29 | 1979-06-30 | 1979-12-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-12-29 | 1983-06-30 | 1983-12-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-12-29 | 1987-06-30 | 1987-12-30 | $7700.00 | Window Closed / Lapsed |