Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: This invention relates to a powdered phenolic resin composition suitable for the production of dry processed resinbonded felt. The phenolic resin composition imparts a good release of the felt from the heated platen or belt and has a rapid cure rate. The powdered phenolic composition is composed of a novolac type phenolic resin, or a mixture of novolac and resole type with an aromatic carboxylic acid as an additive. The resin mixture has a bulk density of 0.29-0.36 gm/cm.sup.3, and contains 0.3-5 parts by weight of the aromatic carboxylic acid to 100 parts by weight of phenolic resin. Said aromatic carboxylic acid has the formulaR--Ar--COOHwhereinR is selected from hydrogen, hydroxy or alkoxy groups, andAr is selected from phenyl, phenylalkenyl or phenylalkyl groups.

Abstract: 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.

Abstract: A color developer for pressure-sensitive copying papers is prepared by mixing a para-substituted difunctional phenol-aldehyde condensate and tri- or higher-functional phenol-aldehyde condensate. The tri- or higher-functional phenol-aldehyde condensate can be modified by a polyvalent metal.

Abstract: A color developer for pressure-sensitive copying paper is prepared by mixing a polyvalent metal salt of a para-substituted difunctional phenol-aldehyde condensate and a tri- or higher-functional phenol-aldehyde condensate and/or a polyvalent metal modified tri- or higher-functional phenol-aldehyde condensate.

Abstract: A friction material useful in automobile brakes and the like, comprises as a reinforcing agent steel wool coated with a thermosetting resin such as a phenolic resole resin.

Abstract: 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.

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: 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: A process is provided for making a prilled product from a molten substance wherein steam or heated gas is passed through the nozzle which produces the prilled product prior to the introduction of the molten substance through the nozzle at the beginning of the process.

Abstract: In a process for making a prilled product from a molten substance therefor steam or heated gas is intermittently introduced into the prilling apparatus to clean the apparatus. In one embodiment the molten substance is passed through a filter zone prior to introduction to a nozzle provided with orifices to produce the prilled product and the flow of molten substance through the filter zone is periodically interrupted and steam or heated gas is passed through the filter zone in the direction opposite to the flow of molten substance to clean the filter zone. More than one filter zone can be operated in parallel so that while one filter zone is being cleaned, molten substance is passed through another filter zone to provide for continuous operation of the process.

Abstract: A nozzle pre-heating device is provided for use in a tower for prilling molten substances. The device comprises a pre-heating chamber which is open only at the upper portion thereof for pre-heating a prilling nozzle and is closed at the bottom to shield the nozzle from the cooling effects of upper flowing gas in the prilling tower. The device is provided with means for moving either the nozzle or the pre-heating device from proximity to one another when the pre-heating device is not in use, thereby permitting free flow of the molten substance from the nozzle during normal operation of the prilling tower.

Abstract: An improved prilling tower is provided for the prilling of molten substances wherein a receiver equipped with an exhaust conduit is positioned below the nozzle during pre-heating of the nozzle prior to normal operation, after the end of a normal operating cycle or when the nozzle is replaced during operation of the prilling tower. Means are provided for moving either the receiver or the nozzle in a horizontal direction so that the nozzle is out of proximity with the receiver during normal operation of the prilling tower. More than one nozzle or more than one receiver can be employed in a prilling tower to provide for continuous operation of the prilling tower during replacement or cleaning of the nozzles.

Abstract: A color developer for pressure-sensitive copying papers is prepared by mixing a para-substituted difunctional phenol-aldehyde condensate and tri- or higher-functional phenol-aldehyde condensate. The tri- or higher-functional phenol-aldehyde condensate can be modified by a polyvalent metal.

Abstract: A color developer for pressure-sensitive copying paper is prepared by mixing a polyvalent metal salt of a para-substituted difunctional phenol-aldehyde condensate and a tri- or higher-functional phenol-aldehyde condensate and/or a polyvalent metal modified tri- or higher-functional phenol-aldehyde condensate.

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: A method for manufacturing foundry sand cores and molds, which comprises preforming a foundry sand mixture comprising sand, a vinyl acetate resin and an organic solvent for said resin and optionally a resin selected from the group consisting of aromatic thermoplastic resins and aromatic thermosetting resins, and thereafter removing said solvent from the preformed foundry sand mixture by evaporation.