Phenolic Or Amine Or Ketone Condensate With Aldehyde Patents (Class 523/145)
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Patent number: 4501836Abstract: A polymeric binder composition for refractory aggregates is disclosed. The binder is a resole type phenolic resin, solvent and a tar, pitch or mixtures thereof. The solvent has a boiling point of greater than 75.degree. C. and is added to the resole type phenolic resin to impart a viscosity range of between 1 to 1000 poise. The tar/pitch component is combined in the solvent-resin mixture, and is incorporated within the ratios of 30:70 to 70:30 with relation to the phenolic resin. The binder results in a high carbon binder.Type: GrantFiled: May 19, 1983Date of Patent: February 26, 1985Assignee: Sumitomo Durez Company, Ltd.Inventors: Masayuki Nakamura, Masaaki Tsuriya, Masahiko Funabashi
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Patent number: 4495316Abstract: A suspension or solution containing an acid-curable fluoride-containing resin which is useful in a foundry process is disclosed. The fluoride-containing resin is curable at room temperatures and above by the addition of a strong acid catalyst. The resin is preferably a phenolic resole resin or a furan-type resin. The fluoride-containing resins, when used in a foundry process are preferably admixed with a foundry sand and a strong acid catalyst. The coated sand is then shaped into the form of a foundry core and is allowed to cure at room temperature or above to a foundry core having excellent tensile strength.Type: GrantFiled: September 23, 1976Date of Patent: January 22, 1985Assignee: Acme Resin CorporationInventor: David R. Armbruster
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Patent number: 4487868Abstract: A foundry core composition containing a rapid-curing furfuryl alcohol and phenolic resole resin system useful in the "hot-box" process is provided. This composition includes an acidic curing agent of low toxicity whose catalytic activity is enhanced by the presence of a water-soluble polymeric polyhydroxy compound.Type: GrantFiled: May 25, 1983Date of Patent: December 11, 1984Assignee: Acme Resin CorporationInventors: David R. Armbruster, Luis R. Rodriguez
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Patent number: 4483946Abstract: A shaped, refractory, heat-insulating liner comprises particulate refractory material, a water-soluble borate compound and, as binder, starch and a urea-formaldehyde resin. The starch helps provide suitable transverse strength, the resin protects the starch from moisture and promotes good surface properties and the borate compound enhances the transverse strength and the integrity of the liner at high temperature. The article e.g. a slab is useful for lining metallurgical vessels e.g. tundishes.Type: GrantFiled: January 24, 1983Date of Patent: November 20, 1984Inventors: Andrew Barnes, Raymond W. Yates
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Patent number: 4482654Abstract: Foundry sand grains coated with a binder composition which comprises 100 wt. parts of methylolmelamine or alkylated methylolmelamine and 5 to 100 wt. parts of a water-soluble organic compound having a hydroxyl group. The sand grains coated with the composition are effective in a low-temperature foundry, especially for forming a core in an aluminum-alloy foundry.Type: GrantFiled: January 20, 1983Date of Patent: November 13, 1984Assignees: Daicel Chemical Industries, Ltd., Shinto Kogio Ltd.Inventors: Kazuyuki Nishikawa, Katsumi Hirao, Kazuhiko Mizuguchi, Hiroshi Suzuki
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Patent number: 4469517Abstract: A process is provided for treating impure silica-containing sands to make them more suitable for foundry use. The sands are treated with aqueous alkali metal silicate solutions and the resulting mixture is heated before the sands are coated with a resin binder. Foundry cores and molds prepared with these treated sands show improved hot and cold tensile strengths.Type: GrantFiled: January 20, 1983Date of Patent: September 4, 1984Assignee: Acme Resin CorporationInventor: Richard C. Cooke, Jr.
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Patent number: 4468359Abstract: A foundry moulding composition comprising (a) a granular refractory material, and (b) from 0.5% to 8% based on the weight of the refractory material of a binder comprising (i) an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50% to 75% and said resin having a weight average molecular weight (M.sub.w) of from 600 to 1500, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.2:1 to 1.2:1 and (ii) at least one silane in an amount of from 0.05% to 3% based on the weight of said aqueous solution, said binder being curable by contact therewith of from 5% to 60% based on the weight of said aqueous solution of a C.sub.1-3 alkyl formate.Type: GrantFiled: November 9, 1982Date of Patent: August 28, 1984Assignee: Borden (UK) LimitedInventors: Peter H. R. B. Lemon, Jeffrey D. Railton, Peter R. Ludlam, Timothy J. Reynolds
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Patent number: 4468486Abstract: A resin coated sand for shell-molding processes is provided comprising the coating of foundry sand or aggregates with a phenolic resin and a carboxylic acid salt. The carboxylic acid salt is selected from a carboxylic acid salt of an element selected from groups Ia, Ib, IIa, IIb, IIIa, IVa, Va, VIb, VIIa, VIIb or VIII of the Periodic Table of Elements. The proportion of carboxylic acid salt to phenolic resin is from 0.5 to 40 parts carboxylic acid salt to 100 parts phenolic resin. This resin coated sand produces shell-molds having excellent properties for casting, and allows the molded article to be removed in an easy and efficient manner.Type: GrantFiled: November 2, 1982Date of Patent: August 28, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Noriaki Matsushima, Yukio Saeki, Yukio Tokunaga
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Patent number: 4462834Abstract: The exposed surface of a molten metal, ferrous or non-ferrous in a ladle is covered by an expanding insulating ladle covering compound that is capable of absorbing and removing non-metallic inclusions in a predictable volume. The compound includes burnt lime in amounts between 56% and 60% by weight, aluminum dross, including Al.sub.2 O.sub.3 in amounts between 22% and 30% by weight, fluorspar in amounts between 7% and 9% by weight, and acid treated graphite in amounts between 1% and 4% by weight.Type: GrantFiled: June 16, 1983Date of Patent: July 31, 1984Inventor: Micheal D. LaBate
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Patent number: 4460716Abstract: A process for preparing resin coated sand for shell molding foundry operations is disclosed wherein the resin utilized is a phenolic resin containing a bromophenol. The resin coated sand has improved shake-out properties and is especially formulated for low melting metals such as aluminum and magnesium castings.Type: GrantFiled: June 16, 1983Date of Patent: July 17, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Yukio Saeki, Shigeru Nemoto, Yukio Tokunaga
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Patent number: 4460717Abstract: A resin coated sand for shell-molding foundry operations having improved shake-out properties for molds prepared therefrom is disclosed. Also disclosed are methods of producing said sand. The foundry aggregates or sand are coated with a phenolic resin containing from 0.2 to 40 parts of an aromatic nitro compound per 100 parts of phenolic resin. The resin may be a novolac type, a resole type or a mixture of the two types of phenolic resins. Suggested aromatic nitro compounds are nitrophenols, dinitrophenols and nitronaphthalenes. The process is extremely useful for coating lower melting temperature metals such as aluminum and magnesium.Type: GrantFiled: June 16, 1983Date of Patent: July 17, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Yukio Saeki, Shigeru Nemoto, Yukio Tokunaga
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Patent number: 4459375Abstract: An improved resin coated sand for use in foundry shell-molding applications is disclosed which has increased resistance to thermal shock at the time of pouring. The improved product uses a phenolic resin as binder with aromatic compounds selected from the following generic formulae: ##STR1## The foundry aggregates are mixed with the phenolic resin and organic compounds under conventional mixing conditions to form a sand-resin mixture that can be formed into shell-molds. Upon casting the molten metal into these molds, the abrupt thermal expansion of the coated sand is controlled to eliminate the cracking that occurs when conventional phenolic-sand mixtures are employed.Type: GrantFiled: March 28, 1983Date of Patent: July 10, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Yukio Saeki, Yukio Tokunago
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Patent number: 4459376Abstract: A process for the preparation of a resin-coated sand for use in shell-molding operations wherein the molding operation is designed for metals such as aluminum, magnesium and their alloys which have a lower-melting temperature than iron. The process involves the coating of foundry sand with a phenolic resin incorporating a carbonate and/or bicarbonate of elements selected from groups Ia, IIa, IIIb, IVb, Vb, VIb, VIIb or VIII. This process produces a resin-coated sand with improved shake-out properties of the casting molds.Type: GrantFiled: October 19, 1982Date of Patent: July 10, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Noriaki Matsushima, Yukio Saeki, Yukio Tokunaga
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Patent number: 4459377Abstract: An improved resin coated sand for use in foundry shell-molding applications is disclosed which has increased resistance to thermal shock at the time of pouring. The improved product uses a phenolic resin as binder with aromatic compounds selected from the following generic formulae: ##STR1## wherein m, n, x and y are integers. The foundry aggregates are mixed with the phenolic resin and organic compounds under conventional mixing conditions to form a sand-resin mixture that can be formed into shell-molds. Upon casting the molten metal into these molds, the abrupt thermal expansion of the coated sand is controlled to eliminate the cracking that occurs when conventional phenolic-sand mixtures are employed.Type: GrantFiled: March 28, 1983Date of Patent: July 10, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Yukio Saeki, Tosaku Amakawa, Shigeru Nemoto
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Patent number: 4452927Abstract: Resin coated sand for foundry shell molding operations is provided which eliminates the cracking of the molds at the time of pouring. In conventional phenolic bonded sand molds, the abrupt thermal expansion caused by the pouring of the molten metal into the mold causes the mold to crack. The resin coated sand, in this invention, is composed of foundry sand or aggregates coated with a phenolic resin which has incorporated therein, a polyethylene glycol of high molecular weight. This improved coated sand eliminates cracking at pouring and does not impair the shake-out property of the molds.Type: GrantFiled: January 5, 1983Date of Patent: June 5, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Noriaki Matsushima, Yukio Saeki, Yukio Tokunaga
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Patent number: 4452926Abstract: An improved resin binder for shell-molding operations having improved shake-out properties is disclosed. The resin binder utilizes a lubricant-containing phenolic resin of the novolac or resole type, or a mixture of novolac and resole types, incorporated therewith is an organic chloride. The organic chloride is characterized by having 20% by weight of the heating loss in the temperature range of 130.degree. to 550.degree. C. The organic chloride may be selected from chloride-containing polymers and cyclo-organic chlorides. Chlorinated polymeric material may be selected from polyvinyl chlorides, polyvinyldene chloride resins, chlorinated paraffins and chlorinated polyolefins.Type: GrantFiled: November 5, 1982Date of Patent: June 5, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Noriaki Matsushima, Yukio Saeki, Hajime Kirabayashi
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Patent number: 4448234Abstract: A hydrogen peroxide system or composition for use in resin polymerization comprises a mixture of a major part of concentrated (70%) hydrogen peroxide admixed with minor amounts of phosphoric acid, a halo-substituted acid, such as hydrochloric acid, fluoboric acid or hydrofluoric acid, and sodium perborate. The peroxide composition is characterized by its storage stability, resistance to detonation, zero flammability, ease of handling and improved catalytic properties in the polymerization of certain resins. This hydrogen peroxide composition is compatible for use with a variety of organic peroxides which have been used for resin condensation polymerization and may be used in conjunction therewith. This hydrogen peroxide composition may be safely mixed with resins and resin prepolymers on the sand prior to use.Type: GrantFiled: August 5, 1982Date of Patent: May 15, 1984Assignee: CL Industries, Inc.Inventors: Brian D. Kelley, Patrick H. Stewart
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Patent number: 4427800Abstract: Refractory shaped articles are prepared by heating refractory mixes comprised of refractory particles and a liquid phenolic resole resin having a methylol group index of about 0.8 or less and a free moisture content of about 8 weight percent or less.Type: GrantFiled: February 12, 1982Date of Patent: January 24, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Masayuki Nakamura, Masaaki Tsuriya
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Patent number: 4426484Abstract: The cure of resin compositions comprising a mixture of a resole type phenol aldehyde resin and a novolac type phenol formaldehyde resin is improved by employing resorcinol as all or part of the phenolic component in the novolac type resin. The resin compositions are particularly useful as binders for foundry sand.Type: GrantFiled: October 14, 1981Date of Patent: January 17, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Yukio Saeki, Katsuyuki Tanaka
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Patent number: 4426467Abstract: A foundry molding composition comprising,(a) a granular refractory material;(b) about 0.8 to 5.0% of an alkaline phenolic resin based on the weight of the refractory material;(c) about 25 to 110% of a lactone based on the weight of the phenolic resin.Type: GrantFiled: January 12, 1981Date of Patent: January 17, 1984Assignee: Borden (UK) LimitedInventors: Ingmar P. Quist, Jeffrey D. Railton, Peter H. R. B. Lemon
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Patent number: 4421873Abstract: A foundry composition adaptable to forming cores and molds comprising a foundry aggregate, a binder therefor, a catalyst and an amine, the binder being a substituted phenol.Type: GrantFiled: August 25, 1982Date of Patent: December 20, 1983Assignee: International Minerals & Chemical Corp.Inventors: Charles E. Seeney, John F. Kraemer, Nancy C. Varnum
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Patent number: 4418161Abstract: This invention relates to a method for the production of an improved resin coated lubricated sand for use in shell molding processes, wherein the resin coated sand is especially useful in casting operations using aluminum, magnesium and their alloys.The sand is coated with a phenolic type resin containing a lubricant and an additive to assist in the thermal decompositions of the binder to provide a more efficient removal of the sand grains. The additive is an organic bromide compound of the type: ##STR1## wherein: n and m are integers 0, 1 or 2, and n and m cannot be O at the same time.B.sub.r position is ortho to --oxx is selected from: --H, --C.sub.2 H.sub.4 OH, --CH.sub.2 -- CH.dbd.CH.sub.2 and --CH.sub.2 --CH BR--CH.sub.2 BR.Type: GrantFiled: August 20, 1982Date of Patent: November 29, 1983Assignee: Sumitomo Durez Company, Ltd.Inventors: Noriaki Matsushima, Yukio Saeki, Yukio Tokunaga
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Patent number: 4403076Abstract: A fast curing shell molding composition having the tensile strength of a conventional novolac resin when cured contains a fast curing novolac resin comprising a methylene chained polyphenylol wherein a major portion of the methylene linkages are coupled to adjacent phenylol groups at the o-o' and p-p' position, wherein at least about 19% of the methylene linkages are coupled to adjacent phenylol groups at the o-o' portions, and wherein at least about 3% of the total number of methylene linkages are coupled to adjacent phenylol groups at the p-p' positions. The shell molding composition is produced from the fast curing novolac resin by uniformly coating refractory granules with the fast curing resin. The fast curing novolac resin can be prepared by blending a conventional novolac resin with a novolac resin having a large proportion of methylene linkages coupled to adjacent phenylol groups at the o-o' position.Type: GrantFiled: March 5, 1982Date of Patent: September 6, 1983Assignee: Pacific Resins & Chemicals, Inc.Inventor: Roderick A. McDonald
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Patent number: 4397967Abstract: A fast curing shell molding composition having the tensile strength of a conventional novolac resin when cured contains a fast curing novolac resin comprising a methylene chained polyphenylol wherein a major portion of the methylene linkages are coupled to adjacent phenylol groups of the o-o' and p-p' position, wherein at least about 19% of the methylene linkages are coupled to adjacent phenylol groups at the o-o' portions, and wherein at least about 3% of the total number of methylene linkages are coupled to adjacent phenylol groups at the p-p' positions. The shell molding composition is produced from the fast curing novolac resin by uniformly coating refractory granules with the fast curing resin. The fast curing novolac resin can be prepared by blending a conventional novolac resin with a novolac resin having a large proportion of methylene linkages coupled to adjacent phenylol groups at the o-o' position.Type: GrantFiled: July 14, 1980Date of Patent: August 9, 1983Assignee: Georgia-Pacific CorporationInventor: Roderick A. McDonald
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Patent number: 4387173Abstract: Compositions for forming carbon-containing refractory brick or shape comprising a refractory filler, a binder for said filler and a hardening agent for said binder, said binder comprising a mixture of polymers formed by the homopolymerization of resorcinol. Compositions for forming a carbon-containing refractory brick or shape as above described are also disclosed in which a basic refractory filler is employed and hardening agents are unnecessary. Methods of forming carbon-containing refractory brick or shape are also disclosed involving milling of a dry binder comprising a mixture of polymers formed by the homopolymerization of resorcinol with the refractory filler or mixture of a solution of such a binder material with the refractory filler, either of which may be conducted at ambient temperature.Type: GrantFiled: April 16, 1981Date of Patent: June 7, 1983Assignee: General Refractories CompanyInventors: Francis W. Henry, Jr., Merrill Wood, Jr., Ljubisa Rankovic
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Patent number: 4379866Abstract: Tris (hydroxymethyl) nitromethane is used as the formaldehyde-source, cross-linking agent for a phenol-formaldehyde or resorcinol polymer resin binder system for a plugging refractory to enhance the plugging refractory's ability to withstand residence periods in a mud gun without premature solidification.Type: GrantFiled: September 14, 1981Date of Patent: April 12, 1983Assignee: General Refractories CompanyInventors: Francis W. Henry, Jr., Subrata Banerjee
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Patent number: 4371648Abstract: A composition containing furfuryl alcohol and an ester of a polyol and resin acid; and use thereof in foundry binders.Type: GrantFiled: May 12, 1980Date of Patent: February 1, 1983Assignee: Ashland Oil, Inc.Inventors: John J. Gardikes, Young D. Kim
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Patent number: 4371649Abstract: Process of binding aggregates by mixing aggregates with resin binder and vacuum-activated catalyst, applying a partial vacuum to the mixture to activate the catalyst, and curing the binder.Type: GrantFiled: July 16, 1981Date of Patent: February 1, 1983Inventor: Eduardo Iglesias Hernandez
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Patent number: 4366268Abstract: A molding sand for use in a molding process employing a microwave radiation for curing the molding sand. The molding sand comprises a new sand, a carbonized resin coated sand and a thermosetting or thermoplastic resin. The carbonized resin coated sand is preferably subjected to a scrubbing treatment prior to the admixture thereof with the new sand.Type: GrantFiled: June 23, 1981Date of Patent: December 28, 1982Assignee: Kabushiki Kaisha Komatsu SeisakushoInventors: Akio Yamanishi, Kanichi Sato, Takashi Higashino
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Patent number: 4360615Abstract: Modified tall oil pitch is blended with a metallurgical addition agent and briquetted, extruded, molded, pelletized, or tabletized into a unitary composition. The tall oil pitch is modified chemically to increase the molecular weight and improve the binding properties.Type: GrantFiled: March 9, 1981Date of Patent: November 23, 1982Assignee: American Cyanamid CompanyInventors: Samuel S. Wang, Morris E. Lewellyn
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Patent number: 4345003Abstract: A phenolic resin binder useful for hot coating foundry sand and comprising a mixture of a solid resol phenolic resin and a lubricant is provided in the form of beads or rods of diameter of about 0.5 to 7 mm and a length of about 0.5 to 30 mm. The beads or rods can be formed directly from a molten mixture of the components or the molten mixture can first be solidified and thereafter formed into such beads or rods. The process for the hot coating of foundry sand with the phenolic resin binder and the resulting foundry compositions, molds and cores are also disclosed.Type: GrantFiled: December 4, 1980Date of Patent: August 17, 1982Assignee: Sumitomo Durez Company, Ltd.Inventors: Noriaki Matsushima, Shigeru Nemoto
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Patent number: 4336179Abstract: A granular composition is provided that is especially useful for the preparation of foundry cores and molds. Incorporated in the composition is a novel resin binder that imparts rapid curing properties to the composition.Type: GrantFiled: March 19, 1981Date of Patent: June 22, 1982Assignee: Acme Resin CorporationInventor: Raja Iyer
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Patent number: 4317896Abstract: A binder for foundry aggregate capable of being catalytically cured with a polyisocyanate and an alkaline catalyst comprising in combination, as a major portion, a butylated phenol-formaldehyde resin, a lesser amount of a resole resin and a still lesser amount of a novolac resin.Type: GrantFiled: December 10, 1980Date of Patent: March 2, 1982Assignee: International Minerals & Chemical Corp.Inventor: Melville J. Holik