| US 7,475,717 B2 | ||
| Mold | ||
| Kazuyoshi Chikugo, Tokyo (Japan); Hidemi Ukai, Tokyo (Japan); Koichi Murakami, Tokyo (Japan); and Koshichi Ogawa, Kanagawa (Japan) | ||
| Assigned to Ishikawajima-Harima Heavy Industries Co., Ltd., Tokyo (Japan) | ||
| Filed on Aug. 24, 2007, as Appl. No. 11/844,469. | ||
| Application 11/844469 is a division of application No. 10/547774, filed on Sep. 01, 2005, granted, now 7,281,566. | ||
| Claims priority of application No. 2003-058713 (JP), filed on Mar. 05, 2003; application No. 2004-023863 (JP), filed on Jan. 30, 2004; and application No. PCT/JP2004/002708 (JP), filed on Mar. 04, 2004. | ||
| Prior Publication US 2007/0295470 A1, Dec. 27, 2007 | ||
| Int. Cl. B22C 9/04 (2006.01) | ||
| U.S. Cl. 164—361 [164/516] | 3 Claims |
| 1. A mold, comprising a porous layer having a three-dimensional porous structure on a surface of a cavity of a shell, said
mold being manufactured by the method comprising the steps of:
scattering and adhering combustible powdery particles around a wax mold, which is a lost pattern, to thereby form a layer
of combustible powdery particles around thereof, wherein said powdery particles have a particle size of from about 0.5 mm
to about 1.0 mm;
coating a film of a ceramic precursor slurry around the wax mold having the layer of the powdery particles formed thereon;
subjecting the wax mold coated with the slurry film to a heat treatment at 100 to 180° C., to thereby dewax only the wax mold
without said combustible powdery particles burning and vanishing; and
firing the slurry film, to thereby burn and vanish the powdery particles in the slurry film and form said three-dimensional
porous structure on said surface of said shell, wherein said three-dimensional porous structure includes a plurality of layers
of pores, each pore having a size of from about 0.5 mm to about 1.0 mm; and
wherein said porous structure has a depth extending from an uppermost surface to a lowermost surface of said porous structure,
said depth being about 2 mm, and wherein said pores are continuous in a direction of said depth with adjacent pores being
partly continuous, wherein said continuity of said pores in said depth direction being a result of said burning and vanishing
of said powdery particles which turn to gas and exit said porous structure.
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