Molded article

Abstract

A molded article contains inorganic powder as a main component and further contains inorganic fiber, organic fiber, a thermosetting resin, and heat expandable particles, the heat expandable particles being present in an amount of 0.5% to 10% by mass based on the total mass of the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the heat expandable particles. The inorganic powder is preferably graphite. The inorganic fiber is preferably carbon fiber. The organic fiber is preferably pulp fiber. The thermosetting resin is preferably a phenol resin.

1 . A method of producing a molded article comprising inorganic powder as a main component and further comprising inorganic fiber, organic fiber, a thermosetting resin, and heat expandable particles, the heat expandable particles being present in an amount of 0.5% to 10% by mass based on the total mass of the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the heat expandable particles and the inorganic powder being present in an amount of 70-80% by mass based on the total mass of the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the heat expandable particles, said method comprising the steps of:
 preparing a stock slurry by dispersing the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and heat expandable particles in a dispersing medium,   forming a wet preform from the stock slurry by a papermaking process, and   drying the preform by heating in a mold to shape the preform while expanding the heat expandable particles.   
     
     
         2 . A molded article comprising inorganic powder as a main component and further comprising inorganic fiber, organic fiber, a thermosetting resin, and heat expandable particles, the heat expandable particles being present in an amount of 0.5% to 10% by mass based on the total mass of the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the heat expandable particles;
 wherein the molded article has a thickness of 0.2 to 5 mm.   
     
     
         3 . The molded article according to  claim 2 , wherein the inorganic powder is graphite, the inorganic fiber is carbon fiber, the organic fiber is pulp fiber, and the thermosetting resin is a phenol resin. 
     
     
         4 . The molded article according to  claim 2 , which is a casting mold. 
     
     
         5 . The molded article according to  claim 2 , having at least one opening and a flange around the opening. 
     
     
         6 . The molded article according to  claim 2 , which is a structure for the manufacture of a casting. 
     
     
         7 . The molded article according to  claim 6 , wherein the structure is selected from the group consisting of a runner, a wall, a pouring cup, a sprue, a choke, a gate, a vent, a flow-off, and a feeder. 
     
     
         8 . A molded article comprising inorganic powder as a main component and further comprising inorganic fiber, organic fiber, a thermosetting resin, and heat expandable particles, the heat expandable particles being present in an amount of 0.5% to 10% by mass based on the total mass of the inorganic powder, the inorganic fiber, the organic fiber, the thermosetting resin, and the heat expandable particles;
 wherein the molded article has at least one opening and a flange around the opening.   
     
     
         9 . The molded article according to  claim 8 , wherein the inorganic powder is graphite, the inorganic fiber is carbon fiber, the organic fiber is pulp fiber, and the thermosetting resin is a phenol resin. 
     
     
         10 . The molded article according to  claim 8 , which is a casting mold. 
     
     
         11 . The molded article according to  claim 8 , having a thickness of 0.2 to 5 mm. 
     
     
         12 . The molded article according to  claim 8 , which is a structure for the manufacture of a casting. 
     
     
         13 . The molded article according to  claim 12 , wherein the structure is selected from the group consisting of a runner, a wall, a pouring cup, a sprue, a choke, a gate, a vent, a flow-off, and a feeder.