Abstract: This invention relates to polyurethane-forming foundry no-bake binder systems comprising a phenolic resin component and polyisocyanate component. The phenolic resin component comprises a blend of (a) polyphenol resin and (b) a phenolic resole resin. The binder systems have reduced phenol and free formaldehyde due to the presence of the polyphenol resin in the phenolic resin component. Foundry shapes are made by the no-bake process and are used in making ferrous and non ferrous metal castings.

Abstract: This invention relates to foundry mixes which comprise a dry foundry aggregate and a polyurethane-forming foundry binder. The binder components include a polyether polyol component and an organic polyisocyanate component which is cured with a liquid tertiary amine catalyst. The foundry mixes are used to prepare foundry shapes made from foundry mixes by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non ferrous metals.

Abstract: This invention relates to polyurethane-forming foundry binder systems which contain a nitrogen-containing aromatic compound selected from the group consisting of 2,2'-dipyridyl, 1,10-phenanthroline, and their substituted alkyl derivatives. The foundry binder systems are particularly useful for making foundry mixes used in the cold-box fabrication process for making foundry shapes. However, the binders systems can also be used to hold foundry shapes, such as molds and cores, together in an assembly.

Abstract: The invention relates to an ester cured no-bake foundry binder system preferably comprising as separate components (a) an aqueous basic solution of a phenolic resole resin; and (b) a hardener comprising (i) a polyphenol resin, and (ii) a liquid ester. Alternatively, the polyphenol resin can be used as a separate component. The foundry binder systems produce foundry shapes with improved tensile strengths when compared to foundry shapes which are prepared from foundry binder systems which do not contain a polyphenol resin.

Abstract: The subject invention relates to foundry mixes comprised of (a) an aqueous basic solution of a phenolic resole resin; (b) a major amount of reclaimed sand which has first been treated with an aqueous non halogenated surfactant solution, and (c) a liquid ester co-reactant.The invention also relates to foundry shapes made with the subject foundry mixes which have improved tensile strengths and scratch hardness when compared to foundry shapes which are prepared from foundry binder systems which do not utilize foundry aggregates which have been mixed with an aqueous surfactant solution.

Abstract: Polyphosphoryl chlorides are used in polyurethane-forming foundry binder systems to extend the bench life of foundry mixes prepared by mixing the binder systems with sand. The foundry mixes are particularly useful for preparing molds and cores used for making metal castings.

Abstract: Certain polyether polyols are used in polyurethane-forming binders to improve the shakeout of molds and cores, made by cold-box and no-bake processes. Such molds and cores are used to make metal castings, particularly from low melting metals such as aluminum.

Abstract: This invention relates to a no-bake process for preparing foundry shapes which utilizes polyurethane-forming binders containing selected polyester polyols. The resulting foundry shapes are particularly useful in preparing castings from low melting metals.

Abstract: Certain polyester polyols are used in polyurethane-forming binders to improve the shakeout of molds and cores, made by a cold-box process, used to make low melting metal castings.

Abstract: This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Abstract: The subject invention relates to foundry binder systems, which are cured with gaseous sulfur dioxide, comprising as separate components:1. a blend of an acrylated epoxy resin and a monoester solvent and;2. an organic solvent; and a blend of an epoxy resin and an aromatic hydrocarbon solvent which is part of component (a), (b), or both.The invention also relates to the use of the foundry binder systems to prepare foundry mixes, foundry shapes, and metal articles.

Abstract: This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Abstract: The subject invention relates to modifiers for aqueous basic solutions of phenolic resins. The modifiers are open-chain ether alcohols or ketone alcohols. They assist in stabilizing the aqueous basic solutions of phenolic resole resins and improve the tensile strength of foundry shapes prepared from foundry mixes made with the aqueous basic solutions.

Abstract: The subject invention relates to a hot box process for forming foundry shapes. The foundry shapes are formed with a mixture of an aggregate and certain aqueous basic solutions of phenolic resole resins which act as binders. The use of these binders results in foundry shapes which are cured by heating at elevated temperatures without requiring an acid-generating curing catalyst.

Abstract: Fiber reinforced molding compounds wherein the resinous matrix is a thermosetting linear polymer characterized in constituting two oligomeric ethylenically unsaturated polyester segments joined through a polyurethane residue and having acryloyl or methacryloyl end groups.

Abstract: A binder containing a phenolic resin, a polyisocyanate, and an organohalophosphate and use thereof.

Abstract: A binder composition containing a phenolic resin, a polyisocyanate, a phosphorus based acid and optionally an acid halide and/or a base, and methods of making and using the same.

Abstract: A binder containing a phenolic resin; a polyisocyanate; a curing component, and a phosphorus halide and use thereof.

Abstract: Thermosettable polymeric cyclopentadiene derivatives, method for preparing polymeric cyclopentadiene derivatives, and use of polymeric cyclopentadiene derivatives in curable binder compositions.

Abstract: A binder is formed by polymerizing or hardening a binding material or composition, an unsaturated polymer or unsaturated monomer or mixtures thereof (polymer solution), wherein at least part of the unsaturation is ethylenic, preferably of vinyl or acrylic type, by free radical polymerization. The free radical polymerization is caused by contacting the unsaturated binding material with a free radical initiator comprising a peroxide and catalytic agent. In the preferred embodiment the binding material is a solution of an ethylenically unsaturated polymer in a solvent of unsaturated monomeric compound or compounds, in which vinyl or acrylic unsaturation is present. The binder is formed upon polymerization which occurs when the unsaturated monomer, polymer or polymer solution is exposed to the free radical initiator. Subjection of the unsaturated monomer, polymer or polymer solution to the initiator begins the formation of free radicals and subsequently the binding composition is polymerized to form the binder.