Abstract: This invention intends to provide a method for filling a foam mixture in a cavity of a metal mold, which method can produce a mold without defects.

Abstract: A molding process which comprises mixing together a particulate aggregate, plural kinds of water-soluble binders, a crosslinking agent causing crosslinking reaction with the binders, a phenol resin, and water, agitating the obtained mixture to prepare a bubbled fluid aggregate mixture, filling the aggregate mixture into a molding cavity, and solidifying the aggregate mixture through the evaporation of water from the mixture to give a mold made from the mixture.

Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.

Abstract: A method is disclosed that monitors and controls the condition of an expandable mixture before injecting it in a mold and that maintains the conditions for filling so as to make a casting mold having a uniform strength. The method comprises (a) a step of measuring the temperature of the expandable mixture, (b) a step of determining each reference value of the one or more characteristic parameters that show a characteristic property of the expandable mixture based on the measured temperature and the predetermined relationship between a characteristic property of an expandable mixture and its temperature, (c) a step of measuring the one or more characteristic parameters that show the condition of the mixing of the expandable mixture, (d) a step of determining whether each characteristic parameter is within the corresponding reference value, and (e) a step of determining whether the expandable mixture has been made under the normal condition or if it needs to be adjusted.

Abstract: An apparatus for molding a mold by pressurizing a foam mixture composed of particles of aggregate, water-soluble binders, and water, and injecting it into a cavity of a heated metal mold that includes a hollow rectangular-parallelepiped body 12 having a bottom plate 14, the bottom plate 14 having an injection hole 13 to inject the foam mixture, a device 10 for containing the foam mixture having functions as a mixing bath to mix particles of aggregate, water-soluble binders, and water, and as a pressurized vessel to inject the foam mixture into the metal mold, and a device 22 for closing and opening the injection hole 13. The apparatus is further provided with a device for measuring a temperature of the particles of aggregate or the foam mixture, the viscosity, and the moisture and a device for communicating gases from the cavity of the metal mold to the outside of the mold so that the particles of aggregate cannot pass through it.

Abstract: This invention relates to an apparatus for molding a mold by pressurizing a foam mixture composed of particles of aggregate, water-soluble binders, and water, and injecting it into a cavity of a heated metal mold. This invention provides an apparatus which can use a foam mixture effectively, can fill the cavity of the metal mold with enough of a foam mixture, and can shorten the time to harden the foam mixture. To achieve these effects, the apparatus for molding a mold is comprised of a hollow rectangular-parallelepiped body 12 having a bottom plate 14, the bottom plate 14 having an injection hole 13 to inject the foam mixture, a means 10 for containing the foam mixture having functions as a mixing bath to mix particles of aggregate, water-soluble binders, and water, and as a pressurized vessel to inject the foam mixture into a metal mold, and a means 22 for closing and opening the injection hole 13.

Abstract: A casting process that employs a collapse-prone core is disclosed. The process includes the steps of mixing one or more kind of an aggregate granular material, one or more kind of a water-soluble binder, and water, to form a mixture of the aggregate granular material, and stirring the mixture to cause it to foam. Such a mixture prevents the generation of undesirable gases when molding a mold and pouring molten metal into the mold.

Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.

Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.