CAST MOLD FORMING COMPOSITIONS AND USES THEREOF

Abstract

The present invention provides a composition for forming a casting mold or a mold liner, comprising solid particles of CaO, SiO, MgO, Al.sub.2O.sub.3 having an average particle size of 20 to 60 μm.

Claims

1. A composition comprising solid particles of CaO, SiO, MgO, Al.sub.2O.sub.3 wherein the average particle size of said solid particles is between about 20 μm to 60 μm, wherein said composition is a casting mold composition.

2. (canceled)

3. A composition of claim 1, wherein said CaO is in the amount of at least 30% wt of the composition.

4. A composition of claim 1, wherein said MgO is in the amount of at least 0.5% wt of the composition.

5. A composition of claim 1, wherein said SiO is in the amount of at least 0.5% wt of the composition.

6. A composition of claim 1, wherein said Al.sub.2O.sub.3 is in the amount of at least 0.5% wt of the composition.

7. A composition of claim 1, wherein CaO is in the amount of between about 30% to 60% wt of the composition.

8. A composition of claim 1, wherein said MgO is in the amount of between about 0.5% to 20% wt of the composition.

9. A composition of claim 1, wherein said SiO is in the amount of between about 0.5% to 5.5% wt of the composition.

10. A composition of claim 1, wherein said Al.sub.2O.sub.3 is in the amount of between about 0.5% to 1.5% wt of the composition.

11. A composition of claim 1, further comprising at least one of Fe.sub.2O.sub.3, TiO.sub.2, K.sub.2O, Na.sub.2O, P.sub.2O.sub.5, Mn.sub.2O.sub.3 and SO.sub.3 and any combinations thereof.

12. A composition of claim 1, wherein said casting mold is a curable material casting mold.

13. A composition of claim 1, wherein said casting mold is a mold-liner.

14. (canceled)

15. (canceled)

16. A method of forming a casting mold comprising the steps of: (a) providing a composition comprising solid particles of CaO, SiO, MgO, Al.sub.2O.sub.3 wherein the average particle size of said solid particles is between about 20 μm to 60 μm; (b) mixing said composition with water so as to form a pliable wet mixture; (c) forming a 3 dimensional mold from said wet mixture; (d) drying said mold so as to form a dry casting mold.

17. (canceled)

18. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features, and advantages thereof, may best be understood by reference to the following detailed description when read with the accompanying drawings in which:

[0020] FIG. 1 shows how the composition of the invention is sprayed to a surface of a molding cast.

[0021] FIGS. 2A-2B show a cast mold after spraying with a composition of the invention.

[0022] FIGS. 3A-3B shows the cured units after stripping of molds. (See concrete unit with (TOP) and without (BOTTOM) application of the composition).

[0023] FIGS. 4A-4B shows cured units after washing the composition with water off the cured concrete surface. TOP: concrete unit with (LEFT) and without (LOWER RIGHT) application of the composition of the invention.

[0024] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0025] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.

Example 1

[0026] 1. The dry composition of the invention is mixed with tap water to the required consistency. For spraying the composition more water is added while for molding the composition (like clay) less water is required.

[0027] 2. The composition is sprayed on the surface of the mold (FIG. 1) or attached to it (in the clay consistency).

[0028] 3. The composition dries on the surface of the mold, or in clay consistency (before the attaching to the mold) for minutes to hours depending on the air temperature (20 min to 1 hour in 30 C, depending on the thickness of the composition) (FIG. 2).

[0029] 4. Concrete is cast in the molds on top the applied composition.

[0030] 5. After curing, the molds are stripped, and the pattern formed by the composition of the invention can be noted on the surface of the concrete that was in contact with the mold (FIG. 3)

[0031] 6. Tap water was used to dissolve the composition from the concrete face, leaving the pattern, voids and spaces on the cured concrete surface (FIG. 4)

[0032] 7. The water with the dissolved composition can be captured and trough evaporation or separation the composition can be used again.

[0033] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.