Abstract: An apparatus and method for forming foundry cores and molds of superior hardness and uniformity in a wide range of sizes includes staging hoppers for storing a first mass of sand coated with a catalyst-polymerizable resin film, and a second mass of sand coated with a catalyst film for polymerizing the resin. In forming the cores or molds these masses are simultaneously and evenly dispersed into a high velocity carrier air-sand stream and directed through a static mixer stage, wherein the resin and catalyst-coated sand particles are intermingled and at least a partial integration of the films takes place, into a shaping mold cavity, wherein the sand mixture hardens into a desired shape. Because the process is fast and continuous and mixing is accomplished without mechanically driven mixing elements, the apparatus and method are particularly well suited to high volume foundry operations wherein resin-catalyst systems having very fast hardening times are utilized.

Abstract: An apparatus and method for forming foundry cores and molds of superior hardness and uniformity in a wide range of sizes includes staging hoppers for storing a first mass of sand coated with a catalyst-polymerizable resin film, and a second mass of sand coated with a catalyst film for polymerizing the resin. In forming the cores or molds these masses are simultaneously and evenly dispersed into a high velocity carrier air-sand stream and directed through a static mixer, wherein the resin and catalyst-coated sand particles are intermingled and at least a partial integration of the films takes place into a shaping mold cavity, wherein the sand mixture hardens into a desired shape. For improved integration of the resin and catalyst films, and for improved core density, air is injected into the air sand stream downline of the static mixer immediately prior to the sand mixture entering the shaping mold.

Abstract: An apparatus and method for forming foundry cores and molds of superior hardness and uniformity in a wide range of sizes includes staging hoppers for storing under pressure a first mass of sand coated with a catalyst-polymerizable resin film, and a second mass of sand coated with a catalyst film for polymerizing the resin. In forming the cores or molds these masses are simultaneously and evenly dispersed from the hoppers into a high velocity carrier air-sand stream and directed through a static mixer, wherein the resin and catalyst-coated sand particles are intermingled and at least a partial integration of the films takes place, into a shaping mold cavity, wherein the sand mixture hardens into a desired shape. The staging hoppers each include a pressurized infeed portion void of sand to provide more even feeding from the hoppers into the air-sand stream to produce cores of improved consistency.