Patents Assigned to Acme Resin Corporation
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Patent number: 5234973Abstract: The present invention provides a binder solution having a low solids level which provides improved tensile properties when used with reclaimed sand. This binder solution comprises an alkaline phenolic resin which is cured at ambient temperature with an ester-functional curing agent. Also provided by this invention are raw batch formulations comprising sand, a binder solution having a low solids level, and a curing agent. These raw batch formulations include embodiments wherein the low solids levels are obtained by the separate addition of a solvent. The methods for producing foundry molds and cores of this invention included those procedures wherein dilution water is used to reduce the solids contents of conventional, relatively high solids content binder solutions.Type: GrantFiled: September 12, 1991Date of Patent: August 10, 1993Assignee: Acme Resin CorporationInventors: S. Raja Iyer, Calvin K. Johnson, Richard C. Cooke
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Patent number: 5077323Abstract: A process for improving the flowability of resin coated sand which comprises the use of a flow promoter with the mixture of sand and resin. Also provided is a foundry mix comprising foundry sand, a resin binder and the flow promoter, as well as a process for making foundry cores and molds using the foundry mix. The resins are ester-curable alkaline phenolic resole resins. The flow promoter is selected from the group consisting of fatty acids, fatty alcohols, fatty amines, fatty amides and fatty alkanolamides.Type: GrantFiled: October 10, 1989Date of Patent: December 31, 1991Assignee: Acme Resin CorporationInventors: Calvin K. Johnson, Richard C. Cooke, Jr., David R. Armbruster
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Patent number: 5036116Abstract: A hardener composition for alkaline phenolic resole resin binders which comprises a solution of a benzylic ether resole resin in an ester. Binder compositions comprising this hardener with alkaline phenolic resole resins are further provided as are foundry molding compositions and methods for making foundry cores and molds using the molding compositions.Type: GrantFiled: October 18, 1990Date of Patent: July 30, 1991Assignee: Acme Resin CorporationInventors: S. Raja Iyer, Sudhir K. Trikha
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Patent number: 5021539Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.Type: GrantFiled: March 24, 1989Date of Patent: June 4, 1991Assignee: Acme Resin CorporationInventors: David R. Armbruster, Merlyn C. Pasion
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Patent number: 4996249Abstract: A process for improving the flowability of resin coated sand which comprises the use of a fluorosurfactant with the mixture of sand and resin. Also provided is a resin binder containing a fluorosurfactant and a foundry mix comprising foundry sand, a resin binder and a fluorosurfactant. The resins used are alkaline phenolic resole resins and acid-curable resins.Type: GrantFiled: April 27, 1989Date of Patent: February 26, 1991Assignee: Acme Resin CorporationInventors: Calvin K. Johnson, Richard C. Cooke, Kwok-Tuen Tse
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Patent number: 4988745Abstract: A hardener composition for alkaline phenolic resole resin binders which comprises a solution of a benzylic ether resole resin in an ester. Binder compositons comprising this hardener with alkaline phenolic resole resins are further provided as are foundry molding compositions and methods for making foundry cores and molds using the molding compositions.Type: GrantFiled: April 27, 1989Date of Patent: January 29, 1991Assignee: Acme Resin CorporationInventors: S. Raja Iyer, Sudhir K. Trikha
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Patent number: 4971132Abstract: A binder composition which comprises an aqueous alkaline solution of a phenolic resole resin and an additive wherein the additive is phenoxyethanol or a derivative of phenoxyethanol.Type: GrantFiled: May 14, 1990Date of Patent: November 20, 1990Assignee: Acme Resin CorporationInventors: David R. Armbruster, Kwok-Tuen Tse
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Patent number: 4929648Abstract: A binder composition which comprises an aqueous alkaline solution of a phenolic resole resin and an additive wherein the additive is phenoxyethanol or a derivative of phenoxyethanol.Type: GrantFiled: March 24, 1989Date of Patent: May 29, 1990Assignee: Acme Resin CorporationInventors: David R. Armbruster, Kwok-Tuen Tse
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Patent number: 4848470Abstract: An improved process for removing from a wellbore in a subterranean formation particulate material bonded together by a cured phenolic resin. The material is contacted with a solvent composition comprising a liquid selected from the groups: N,N-dimethylformamide, N-methyl-2-pyrrolidone and mixtures thereof for a sufficient time to separate the particulate material and then the separated material is removed from the wellbore.Type: GrantFiled: November 21, 1988Date of Patent: July 18, 1989Assignee: Acme Resin CorporationInventor: Charles J. Korpics
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Patent number: 4848442Abstract: An alkoxy-modified phenolic resole resin providing an improved binder for foundry cores and molds. The resin has predominantly ortho-ortho benzylic ether bridges joining the phenolic nuclei in the resin and at least one alkoxymethylene group for every 20 phenolic nuclei.Type: GrantFiled: October 8, 1987Date of Patent: July 18, 1989Assignee: Acme Resin CorporationInventors: Raja Iyer, Rasik C. Shah, Robert A. Laitar
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Patent number: 4785884Abstract: A proppant composed of particulate material coated with a solid thermosetting resin that can consolidate and cure at tempertures below about 130.degree. F. An acidic catalyst in a solvent system is used to cure the resin underground.Type: GrantFiled: January 28, 1988Date of Patent: November 22, 1988Assignee: Acme Resin CorporationInventor: David R. Armbruster
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Patent number: 4740535Abstract: A process for preparing modified phenolic resole resins providing improved binders for refractories and foundry cores and molds. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of an alkaline catalyst followed by further reaction at a pH below 7 in the presence of a catalyst which promotes formation of ortho-ortho benzylic ether bridges between the phenolic nuclei.Type: GrantFiled: March 6, 1987Date of Patent: April 26, 1988Assignee: Acme Resin CorporationInventors: Raja Iyer, Rasik C. Shah
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Patent number: 4723592Abstract: A process for preparing an alkoxy-modified phenolic resole resin useful as the polyhydroxy component of a urethane binder composition. A phenol is reacted with a molar excess of an aldehyde in the presence of an alkaline catalyst and the resulting product is further reacted with a monohydric aliphatic alcohol under acidic conditions.Type: GrantFiled: September 19, 1986Date of Patent: February 9, 1988Assignee: Acme Resin CorporationInventors: Robert A. Laitar, Eduardo Gmez
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Patent number: 4722991Abstract: A terpolymer is prepared from phenol, furfuryl alcohol and formaldehyde wherein a substantial amound of the furfuryl alcohol is catalytically reacted by means of a water soluble multivalent metal salt catalyst, and wherein the reaction is carried out under essentially hydrous conditions.Type: GrantFiled: May 23, 1986Date of Patent: February 2, 1988Assignee: Acme Resin CorporationInventor: David R. Armbruster
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Patent number: 4713294Abstract: A foundry shell core and mold composition comprises particulate matter coated with a curable phenolic-furan resin. The process for making the resin coated particulate matter substantially eliminates the sue of hexamethylene tetramine.Type: GrantFiled: May 23, 1986Date of Patent: December 15, 1987Assignee: Acme Resin CorporationInventors: David R. Armbruster, Calvin K. Johnson
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Patent number: 4698377Abstract: Esters of alkoxy acids, particularly those of 3-alkoxypropionic acids are used as part or all of the polar solvent in solvent systems for binder compositions containing phenolic resins and polyisocyanates.Type: GrantFiled: September 26, 1986Date of Patent: October 6, 1987Assignee: Acme Resin CorporationInventor: Robert A. Laitar
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Patent number: 4694905Abstract: The present invention relates to coated particulate matter wherein the particles are individually coated with a cured combination of phenolic/furan resin or furan resin to form a precured resin coating on a proppant such as sand, thereby substantially improving the chemical resistance of the proppant over one having a straight phenolic precured coating.Another embodiment of this invention involves the use of multiple resin coatings on the particulate matter to form a final layered coating containing the desired amount of cured resin. This multiple coating of particulate material results in a final coated product that has a smoother and more uniform surface than particulate material having its entire resin coating applied in a single operation.Type: GrantFiled: May 23, 1986Date of Patent: September 22, 1987Assignee: Acme Resin CorporationInventor: David R. Armbruster
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Patent number: 4677187Abstract: Furfuryl alcohol-formaldehyde resins which can be prepared by using a water soluble multivalent metal salt as the catalyst, thereby eliminating the use of an acid catalyst and the necessary attention it requires.Type: GrantFiled: May 23, 1986Date of Patent: June 30, 1987Assignee: Acme Resin CorporationInventors: David R. Armbruster, Merlyn Pasion
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Patent number: 4668759Abstract: A process for preparing modified phenolic resole resins providing improved binders for refractories and foundry cores and molds. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of an alkaline catalyst followed by further reaction at a pH below 7 in the presence of a catalyst which promotes formation of ortho-ortho benzylic ether bridges between the phenolic nuclei.Type: GrantFiled: July 31, 1985Date of Patent: May 26, 1987Assignee: Acme Resin CorporationInventors: Raja Iyer, Rasik C. Shah
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Patent number: 4657950Abstract: Refractory shaped articles are prepared by heating refractory mixes comprised of refractory particles and an alkoxy modified phenolic resole resin having at least one alkoxy methylene group for every 20 phenolic hydroxyl groups.Type: GrantFiled: October 12, 1984Date of Patent: April 14, 1987Assignee: Acme Resin CorporationInventors: Raja Iyer, Rasik C. Shah, Robert A. Laitar