Abstract: Novel resin binders for foundry sand molds and cores are provided by reacting a polyol component comprising a phenol ketone resin, a reactive solvent and a cross-linking agent in a solution for these components with a solution of an organic polyisocyanate. The foundry binder cures rapidly at ambient temperature in the presence of a tertiary amine curing agent to provide strong foundry molds and cores. Polyether polyols may also be incorporated in the polyol component of the novel resin binder.

Abstract: A method and apparatus are described. A thermosetting molding material, suitably a synthetic resin composition such as a phenolic molding composition, is initially heated and plasticized. The plasticized mass is passed as a stream through an injection nozzle which is maintained at a temperature sufficiently high to keep the mass in a plasticized condition but sufficiently low to avoid any substantial curing or setting-up of the mass. The plasticized mass is next passed through a temperature-controlled manifold maintained at a temperature sufficiently high to keep the mass in a plasticized condition but sufficiently low to avoid any substantial curing or setting-up of the mass. In the manifold the plasticized stream is divided into two or more smaller streams which are passed through a plurality of outlets into a plurality of partially open, heated molds. The mold cavities are maintained at temperatures sufficiently high to cure the thermosetting molding material.

Abstract: This invention relates to polymer blends having improved hydrolytic stability, moldability, fire retardancy and dielectric strength which comprise, in admixture, (1) a linear aromatic polyester prepared from an aromatic dicarboxylic acid and bisphenol, and (2) polyphenylene sulfide. Such blends have a weight proportion of the polyphenylene sulfide in the range of above about 5 weight percent to less than about 60 weight percent, based on the admixture of the sulfide polymer and the polyester.

Abstract: This invention relates to polymer blends having improved hydrolytic stability which comprise, in admixture, (1) a linear aromatic polyester of monomer residues consisting essentially of residues of a dicarboxylic acid and a bisphenol, and (2) an MBS polymer.

Abstract: An improved molding apparatus for injection-compression molding thermosetting materials is described. The apparatus comprises a stationary platen assembly, a moveable platen assembly and a feed nozzle assembly.The stationary assembly is comprised of a stationary platen member, a heated plate mounted on the support plate and a plurality of mold faces mounted on the heat plate.The movable assembly is comprised of a moveable platen member, a heated plate mounted thereon and a plurality of mold faces mounted on the heat plate aligned with the mold faces on the stationary assembly.The feed, or injection, nozzle assembly is comprised of a cylindrical nozzle member, having an internal temperature controlling means, and a plurality of feed outlets positioned on the periphery.

Abstract: A lubricant-containing binder for the dry hot coat foundry method comprising a solid resol type phenolic resin and a lubricant in an amount of about 0.5 to 10 percent by weight with respect to said phenolic resin.

Abstract: An improved assembly for mounting a part onto a base member is provided by incorporating a tubular insert having a hollow inner core in a mounting hole in the part. A fastener, such as a bolt, machine screw or rivet, may then be inserted through the insert in the mounting hole for attachment to the base member. The tubular insert has an integral flange on the end which engages the fastener. The flange functions as the "washer" in conventional fastener assemblies. When the assembly is subjected to axial compression by the fastener, the insert collapses uniformly in an axial direction to absorb a substantial amount of the total compressive load exerted upon tightening the fastener.

Abstract: An improved assembly for mounting a part onto a base member is provided by incorporating a tubular insert having a hollow inner core in a mounting hole in the part. A fastener, such as a bolt, machine screw or rivet may then be inserted through the insert in the mounting hole for attachment to the base member. When the assembly is subjected to axial compression by the fastener, the insert collapses uniformly in an axial direction to absorb a substantial amount of the total compressive load exerted upon tightening the fastener.

Abstract: This invention relates to polymer blends having improved hydrolytic stability, moldability and fire retardancy which comprise, in admixture, (1) a linear aromatic polyester prepared from an aromatic dicarboxylic acid and a bisphenol, and (2) polyphenylene sulfide.

Abstract: Phenolic resin particles which are useful as friction particles for use in friction elements such as brake linings, clutch facings or other braking devices are produced by dispersing a liquid, heat curable phenolic resin in a paraffinic oil having a viscosity of at least about 1,000 SUS at 100.degree. F. at a temperature of about 100.degree. to about 175.degree. C. Preferred friction particles are prepared from phenolic resins containing benzylic ether linkages in the presence of hot oil or by other heating methods. Friction elements containing such particles are also described.

Abstract: Phenolic novolak resins are described which are structurally characterized as having from about 55% to about 90% of the available theoretical paraphenyl linkages in the resin chain bridged to a phenyl group. The resin compositions of this invention provide extended resin stability at relatively low temperatures without significant adverse affect on the cure speed at the molding temperature. The resins are especially suited for use in runnerless injection or cold manifold molding processes, but can also be used in transfer, compression and injection molding processes.

Abstract: Phenolic novolak resins are described which provide extended resin stability at relatively low temperatures without significant adverse affect on the cure speed at the molding temperature. The resins are especially suited for use in runnerless injection or cold manifold molding processes, but can also be used in transfer, compression and injection molding processes.

Abstract: Phenolic novolak resins are described which are structurally characterized as having from about 55% to about 90% of the available theoretical paraphenyl linkages in the resin chain bridged to a phenyl group. The resin compositions of this invention provide extended resin stability at relatively low temperatures without significant adverse affect on the cure speed at the molding temperature. The resins are especially suited for use in runnerless injection or cold manifold molding processes, but can also be used in transfer, compression and injection molding processes.

Abstract: An improved nozzle feed assembly is described. The assembly includes temperature-controlled member, preferably cylindrical in shape, having a closed end and an open end. The open end is fitted with standard threads to facilitate attachment of the nozzle member to the feed barrel of a conventional screw-type molding machine. The nozzle member has an internal temperature controlling means and a plurality of feed outlets positioned on the periphery of the nozzle member near the closed end. The temperature maintained in the nozzle member is sufficiently high to maintain the thermosetting molding material within the nozzle member in a plasticized state and sufficiently low that no substantial curing of the thermosetting molding material takes place. In an alternate mode, the assembly includes a sleeve member positioned around the periphery of the nozzle member and moveable to cover and uncover the feed outlets in the periphery of the nozzle member.

Abstract: The invention relates to thermoplastic polymeric compositions comprising a linear aromatic polyester of a bisphenol and a dicarboxylic acid admixed with a minor proportion of a perfluoroalkenoxy surface active compound. These compositions which are suitable for use as film or molding compositions exhibit enhanced tensile strength on ageing without substantial detriment to other properties of the polyester.

Abstract: An improved transesterification process for preparation of a linear aromatic polyester comprising bisphenol and dicarboxylic acid monomer units terminated with a carboxylic acid ester groups derived from a long chain aliphatic monofunctional alcohol comprises as the improvement partially transesterifying a diaryl ester of the dicarboxylic acid with the alcohol prior to carrying out the transesterification polymerization reaction of said aryl ester and the bisphenol.

Abstract: This invention relates to a solid phenolic resin composition useful as a binder in the preparation of foundry sand cores and molds which comprises a solid novolac resin and a lubricant-containing solid resole resin wherein the lubricant is incorporated into the resole during the preparation of the solid resole. In a preferred binder composition, the resole component of the binder is prepared in the presence of an alkali metal catalyst and an amine catalyst. The invention also includes the process for preparing sand containing foundry cores and molds from the preferred binder composition and the sand foundry core and mold products of said process.

Abstract: This invention relates to polymer blends having improved hydrolytic stability, moldability and flame retardancy which comprise, in admixture, (1) a linear aromatic polyester prepared from an aromatic dicarboxylic acid reactant and a bisphenol reactant and (2) polyphenylene sulfide. Desirably from about 1 to less than about 50 mole percent of said bisphenol reactant is a halogen-substituted bisphenol.

Abstract: Phenolic novolak resins are described which are structurally characterized as having from about 55% to about 90% of the available theoretical paraphenyl linkages in the resin chain bridged to a phenyl group. The resin compositions of this invention provide extended resin stability at relatively low temperatures without significant adverse affect on the cure speed at the molding temperature. The resins are especially suited for use in runnerless injection or cold manifold molding processes, but can also be used in transfer, compression and injection molding processes.

Abstract: Phenolic novolak resins are described which provide extended resin stability at relatively low temperatures without significant adverse affect on the cure speed at the molding temperature. The resins are especially suited for use in runnerless injection or cold manifold molding processes, but can also be used in transfer, compression and injection molding processes.