Method of making metal casting mold, and mold

Abstract

A method of making a metal casting mold is disclosed. The method comprises the steps of: covering a support pattern by a pulp-molded element; installing a mold flask provided with a depressurizing device, on an upper side of the pulp-molded element; packing heat-resistant particles inside the mold flask; providing a sealing member on an upper surface of the mold flask so as to seal the inside of the mold flask; depressurizing the inside of the mold flask by the depressurizing device, to form a mold comprising the mold flask, the heat-resistant particles, the pulp-molded element and the sealing member; and separating the pulp-molded element from the support pattern. A metal casting mold made by this method is also disclosed.

1 . A method of making a metal casting mold, comprising the steps of:
 covering a support pattern by a pulp-molded element;   installing a mold flask provided with a depressurizing device, on an upper side of the pulp-molded element;   packing heat-resistant particles inside the mold flask;   providing a sealing member on an upper surface of the mold flask so as to seal the inside of the mold flask;   depressurizing the inside of the mold flask by the depressurizing device, to form a mold comprising the mold flask, the heat-resistant particles, the pulp-molded element and the sealing member; and   separating the pulp-molded element from the support pattern.   
     
     
         2 . A metal casting mold comprising:
 a pulp-molded element covering a support pattern;   a mold flask provided with a depressurizing device and installed on an upper side of the pulp-molded element;   heat-resistant particles packed inside the mold flask; and   a sealing member provided on an upper surface of the mold flask so as to seal the inside of the mold flask,   wherein the depressurizing device is operable to depressurize the inside of the mold flask, thereby forming a mold comprising the mold flask, the heat-resistant particles, the pulp-molded element and the sealing member, and allowing the pulp-molded element to be separated from the support pattern.   
     
     
         3 . The metal casting mold according to  claim 2 , wherein the pulp-molded element is made of a natural fiber. 
     
     
         4 . The metal casting mold according to  claim 2 , wherein the pulp-molded element has a thickness of 0.1 mm to 2.0 mm. 
     
     
         5 . The metal casting mold according to  claim 2 , wherein the pulp-molded element is formed by a paper-making screen process. 
     
     
         6 . The metal casting mold according to  claim 2 , wherein the pulp-molded element is formed by a paper pressing process. 
     
     
         7 . A method of making a metal casting mold, comprising the steps of:
 forming a pulp-molded element by using a paper-making pattern mold having a screen provided on a surface thereof;   installing a mold flask provided with a depressurizing device, on an upper side of the pulp-molded element;   packing heat-resistant particles inside the mold flask;   providing a sealing member on a back surface of the mold flask so as to seal the inside of the mold flask;   depressurizing the inside of the mold flask by the depressurizing device, to form a mold comprising the mold flask, the heat-resistant particles, the pulp-molded element and the sealing member; and   separating the pulp-molded element from the paper-making pattern mold.   
     
     
         8 . A method of making a metal casting mold, comprising the steps of:
 forming a pulp-molded element by using a paper-making pattern mold having a screen provided on a surface thereof;   transferring the pulp-molded element to a support pattern;   installing a mold flask provided with a depressurizing device, on an upper side of the pulp-molded element;   packing heat-resistant particles inside the mold flask;   providing a sealing member on a back surface of the mold flask so as to seal the inside of the mold flask;   depressurizing the inside of the mold flask by the depressurizing device, to form a mold comprising the mold flask, the heat-resistant particles, the pulp-molded element and the sealing member; and   separating the pulp-molded element from the support pattern.   
     
     
         9 . A method of making a metal casting mold, comprising the steps of:
 forming a pulp-molded element having a core shape with at least one opening, by a combinational paper-making pattern mold having a molding surface divided into a plurality of regions and covered by a screen;   inserting a depressurizing device from the opening into the pulp-molded element, and packing heat-resistant particles inside the pulp-molded element;   sealing the opening of the pulp-molded element so as to prevent discharge of the heat-resistant particles packed inside the pulp-molded element;   depressurizing the inside of the pulp-molded element by the depressurizing device, to form a core-shaped mold comprising the heat-resistant particles and the pulp-molded element; and   separating the core mold having the pulp-molded element as a surface thereof, from the combinational paper-making pattern mold.   
     
     
         10 . The method according to  claim 7 , which further comprises, after the step of packing heat-resistant particles inside the mold flask, one selected from the group consisting of: a step of sucking air toward the side of a back surface of the paper-making pattern mold; a step of injecting pressurized air from the side of the back surface of the mold flask; and a step of injecting pressurized air from the side of the back surface of the mold flask, while sucking air toward the side of the back surface of the paper-making pattern mold. 
     
     
         11 . The method according to  claim 8 , which further comprises, after the step of packing heat-resistant particles inside the mold flask, one selected from the group consisting of: a step of sucking air toward the side of a back surface of the support pattern; a step of injecting pressurized air from the side of the back surface of the mold flask; and a step of injecting pressurized air from the side of the back surface of the mold flask, while sucking air toward the side of the back surface of the support pattern. 
     
     
         12 . The method according to  claim 9 , which further comprises, after the step of packing heat-resistant particles inside the pulp-molded element, one selected from the group consisting of: a step of sucking air toward the side of a back surface of the combinational paper-making pattern mold; a step of injecting pressurized air from the opening of the pulp-molded element; and a step of injecting pressurized air from the opening of the pulp-molded element, while sucking air toward the side of the back surface of the combinational paper-making pattern mold. 
     
     
         13 . The method according to  claim 7 , which further comprises a step of heating the heat-resistant particles. 
     
     
         14 . The method according to in  claim 13 , wherein a heating temperature of the heat-resistant particles in the step of heating the heat-resistant particles is in the range of 50° C. to 200° C. 
     
     
         15 . The method according to  claim 7 , wherein the pulp-molded element has a thickness of 0.1 mm to 2.0 mm. 
     
     
         16 . The method according to  claim 7 , wherein the step of packing heat-resistant particles inside the mold flask includes a sub-step of packing heat-resistant particles under vibration. 
     
     
         17 . The method according to  claim 9 , wherein the step of packing heat-resistant particles inside the pulp-molded element includes a sub-step of packing heat-resistant particles under vibration. 
     
     
         18 . A metal casting mold made by the method according to  claim 7 , wherein a product molding surface to be in contact with molten metal is a three-dimensional surface composed of the pulp-molded element, and a side behind the pulp-molded element is backed up by the heat-resistant particles and kept in a depressurized state.