Resin Containing Patents (Class 164/526)
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Patent number: 12221553Abstract: A water-based binder solution comprises a thermoplastic binder, greater than or equal to 4 wt % to less than or equal to 20 wt % of a non-aqueous solvent having a boiling point greater than or equal to 100° C. and less than or equal to 175° C., and water. The thermoplastic binder comprises a first polymer strand having a weight average molecular weight (Mw) of from 5,000 g/mol to 15,000 g/mol; and at least one of a second polymer strand having a weight average molecular weight (Mw) of from 10,000 g/mol to 50,000 g/mol and a third polymer strand having a weight average molecular weight (Mw) of from 1,000 g/mol to 5,000 g/mol. A method of monitoring a print head of an additive manufacture process comprises depositing a water-based binder solution on the thermal paper.Type: GrantFiled: July 28, 2022Date of Patent: February 11, 2025Assignee: General Electric CompanyInventors: Arunkumar Natarajan, William C. Alberts
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Patent number: 10577715Abstract: A foundry mixture for making molds used for molding cast metal parts includes foundry sand, a non-aqueous binder, and a cleaning agent that includes calcium oxide. Residual foundry mixture remaining on the cast part after removal from the mold is removed by electrolytic cleaning of the cast part.Type: GrantFiled: April 25, 2018Date of Patent: March 3, 2020Assignee: York Innovators Group, LLCInventors: John E. Hoffman, Jr., Richard A. Hoffman, Sr.
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Patent number: 10239753Abstract: The invention relates to compact and lightweight disposable accumulators for generating electric energy with extremely high energy densities (>1 kWh/kg and >k Wh/liter), which are of immense interest in many areas of application. One possibility for implementing such energy accumulators consists in using metal hydrides in hydrogen generators in which hydrogen is generated by hydrolytically splitting off a proton from water in conjunction with the metal hydride. The chemical energy stored in the hydrogen can then be converted into electric energy in a fuel cell in a second step. Only half of the generated hydrogen originates from the metal hydride during the hydrolysis reaction; the water used for the hydrolysis process supplies the other half.Type: GrantFiled: June 10, 2015Date of Patent: March 26, 2019Assignee: Fraunhofer-Gesellschaft zur förderung der angewandten Forschung e.V.Inventors: Marcus Tegel, Lars Röntzsch, Bernd Kieback
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Patent number: 9963799Abstract: A foundry mixture for making molds used for molding cast metal parts includes foundry sand, a non-aqueous binder, and a cleaning agent that includes calcium oxide. Residual foundry mixture remaining on the cast part after removal from the mold is removed by electrolytic cleaning of the cast part.Type: GrantFiled: May 22, 2015Date of Patent: May 8, 2018Assignee: York Innovators Group, LLCInventors: John E. Hoffman, Jr., Richard A. Hoffman, Sr.
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Patent number: 9744586Abstract: The binder coated refractories comprises the refractory aggregates and the solid-form coating layer which comprises the sugar group as the binder and which is provided to the surface of the refractory aggregates. According to this, the sugar group is used as the binder for bonding the refractory aggregates. Further, even if the sugar group is thermally decomposed, the sugar group emits the carbon dioxide and the water. Therefore, there is little likelihood of emitting the harmful gas. Therefore, it is possible to reduce the environmental pollution. Further, the sugar group is thermally decomposed easily. Therefore, it is possible to manufacture the casting mold having the good breaking property.Type: GrantFiled: May 22, 2015Date of Patent: August 29, 2017Assignee: LIGNYTE CO., LTD.Inventors: Isamu Ide, Toru Seki, Shinji Nishida
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Patent number: 9493602Abstract: The present invention relates to a polyurethane-based binder using isocyanates containing uretonimine and/or carbodiimide groups for producing cores and casting molds, to a mold material mixture containing the binder, and to a method using the binder for producing casting molds.Type: GrantFiled: November 17, 2011Date of Patent: November 15, 2016Assignee: ASK CHEMICALS GMBHInventors: Carsten Cornelissen, Diether Koch, Christian Priebe
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Patent number: 9038708Abstract: A foundry mixture for making molds used for molding cast metal parts includes foundry sand, a non-aqueous binder, and a cleaning agent that includes calcium oxide. Residual foundry mixture remaining on the cast part after removal from the mold is removed by electrolytic cleaning of the cast part.Type: GrantFiled: October 10, 2014Date of Patent: May 26, 2015Assignee: Newton Engine CorporationInventors: John E. Hoffman, Jr., Richard A. Hoffman, Sr.
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Publication number: 20150114589Abstract: A “no-bake” process allows the forming of larger metal castings, by providing longer work times, in the range of about 45 to about 60 minutes. This is achieved using a liquid curing catalyst that is a pyridine, substituted at the second or third position with a moiety having a molecular weight in the range of about 30 to about 100 mwu. Examples of the liquid curing catalyst include 2-ethanolpyridine, 3-chloropyridine and 2-methoxypyridine. When combined with a two-part polyurethane binder precursor and a foundry aggregate, the liquid curing catalyst provides not only the longer work time, but also a strip time that is less than about 167% of the work time, as measured from the point of activating the polyurethane precursors by mixing them in the presence of the curing catalyst.Type: ApplicationFiled: June 7, 2013Publication date: April 30, 2015Inventors: Michael R. Nocera, Gregory P. Sturtz, Jörg Kroker
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Publication number: 20150114588Abstract: A curing agent composition for making foundry molds, comprising 2,6-dihydroxybenzoic acid. In a sand composition for making foundry molds, it is preferable to use simultaneously: an acid-hardening resin which contains both a binder composition for making foundry molds which comprises one or more 5-position-substituted furfural compounds selected from the group consisting of 5-hydroxymethylfurfural and 5-acetoxymethylfurfural, and the curing agent composition for making foundry molds which comprises 2,6-dihydroxybenzoic acid. It is preferable that the content of 2,6-dihydroxybenzoic acid in the curing agent composition is 10 to 80 wt %.Type: ApplicationFiled: March 14, 2013Publication date: April 30, 2015Applicant: KAO CORPORATIONInventors: Takashi Joke, Toshiki Matsuo
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Patent number: 8919421Abstract: A method for producing cores and molds for the foundry industry utilizing a flowable fire-resistant primary molding material. The method includes an acid applied to the flowable fire resistant primary molding material to obtain an acid-coated fire-resistant primary molding material. A binder that can be cured by acid is applied to the acid-coated fire resistant primary molding material to obtain a fire-resistant primary molding material coated with a binder. The fire-resistant primary molding material coated with a binder is then molded into a molded body, and-the molded body is cured. The acid used is a mixture of methane sulfonic acid and at least one sulfur-free acid. The casting molds can be produced having reduced emission of harmful compounds during casting.Type: GrantFiled: May 22, 2009Date of Patent: December 30, 2014Assignee: ASK Chemicals GmbHInventors: Marcus Frohn, Diether Koch, Antoni Gieniec
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Patent number: 8833434Abstract: A method for making hollow metal tubes includes a step combining a polyphenylene sulfide-containing resin with a water soluble carrier resin to form a resinous mixture. The resinous mixture is then extruded to form an extruded resinous mixture. The extruded resinous mixture includes polyphenylene sulfide-containing fibers within the carrier resin. The extruded resinous mixture is contacted (i.e., washed) with water to separate the polyphenylene sulfide-containing fibers from the carrier resin. The polyphenylene sulfide-containing fibers are then coated with a metal layer. The hollow metal tubes are then formed by removing the polyphenylene sulfide-containing fibers.Type: GrantFiled: June 8, 2012Date of Patent: September 16, 2014Assignee: GM Global Technology Operations LLCInventors: James Mitchell, Timothy J. Fuller, Lijun Zou
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Patent number: 8813830Abstract: The invention relates to a molding material mixture for production of molded products for the foundry industry, comprising at least one fire-resistant base molding material and a polyurethane-based binder system comprising a polyisocyanate component and a polyol component. According to the invention, the polyurethane-based binder system comprises a portion of a carboxylic acid diester of a branched alkane diol, said portion being at least 3 weight-%, and a portion of aromatic solvent of less than 10 weight-% of the binder system. A preferable carboxylic acid diester is 2,2,4-trimethyl-1,3-pentandiol-diisobutyrate. The molded products produced from the molding material mixture for the foundry industry are characterized by a high strength and a lower generation of fumes and smoke during pouring.Type: GrantFiled: January 30, 2009Date of Patent: August 26, 2014Assignee: ASK Chemicals GmbHInventors: Christian Priebe, Diether Koch
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Publication number: 20130299120Abstract: A binder for mold material mixtures is a four-component material. It contains at least one phenolic resin component, at least one isocyanate component, at least one alkyl/alkenyl benzene and at least one dialkylated and/or dialkenylated naphthalene. The phenolic resin component acts as the polyol component and contains phenolic resin obtainable from the reaction between a phenol compound and an aldehyde compound. The isocyanate component contains at least one polyisocyanate with at least two NCO groups per molecule. The alkyl/alkenyl benzene has a boiling point above 250° C. The dialkylated and/or dialkenylated naphthalene has a boiling point above 270° C.Type: ApplicationFiled: September 30, 2011Publication date: November 14, 2013Applicant: ASK CHEMICALS GMBHInventors: Christian Priebe, Diether Koch
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Publication number: 20130248138Abstract: The present invention relates to a polyurethane-based binder using isocyanates containing uretonimine and/or carbodiimide groups for producing cores and casting molds, to a mold material mixture containing the binder, and to a method using the binder for producing casting molds.Type: ApplicationFiled: November 17, 2011Publication date: September 26, 2013Applicant: ASK CHEMICALS GMBHInventors: Carsten Cornelissen, Diether Koch, Christian Priebe
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Publication number: 20130251588Abstract: A composition comprising (a) an epoxy resin; and (b) a hydroperoxide composition comprising a t-butyl hydroperoxide solution that contains no more than 7 weight percent water, and use of the compositions to prepare foundry shapes, the foundry shapes prepared by the process, the use of the foundry shapes to prepare cast metal articles, and the cast metal articles prepared by the process.Type: ApplicationFiled: May 1, 2013Publication date: September 26, 2013Applicant: ASK CHEMICALS L.P.Inventors: Wayne D. Woodson, H. Randall Shriver
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Patent number: 8490677Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.Type: GrantFiled: August 31, 2004Date of Patent: July 23, 2013Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 8387683Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.Type: GrantFiled: January 15, 2009Date of Patent: March 5, 2013Assignee: Kao CorporationInventors: Akira Yoshida, Masayuki Osaki, Toshiki Matsuo, Tomofumi Kanzawa
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Publication number: 20120261087Abstract: A process for producing a mold, comprising a step of mixing refractory particles, a water-soluble phenol resin, and a curing agent composition comprising an ester compound, thereby yielding mixed sands, and a step of putting the mixed sands into an original pattern to shape the sands, wherein the refractory particles comprise reclaimed sands that are artificial sands produced by a fusion method in a proportion of 70% or more by weight, the curing agent composition comprises at least one selected from triethylene glycol diacetate, triethylene glycol, 3-phenylpropane-1-ol, and benzyl alcohol.Type: ApplicationFiled: December 20, 2010Publication date: October 18, 2012Inventors: Masahiko Kagitani, Yoshimitsu Ina, Hitoshi Funada
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Publication number: 20120048503Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.Type: ApplicationFiled: November 2, 2011Publication date: March 1, 2012Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 8109319Abstract: A molding process which comprises mixing together a particulate aggregate, plural kinds of water-soluble binders, a crosslinking agent causing crosslinking reaction with the binders, a phenol resin, and water, agitating the obtained mixture to prepare a bubbled fluid aggregate mixture, filling the aggregate mixture into a molding cavity, and solidifying the aggregate mixture through the evaporation of water from the mixture to give a mold made from the mixture.Type: GrantFiled: June 29, 2005Date of Patent: February 7, 2012Assignee: Sintokogio, Ltd.Inventors: Norihiro Asano, Toshihiko Zenpo, Masaya Hotta, Kazuyuki Nishikawa
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Patent number: 8096346Abstract: A method of casting a base of high-power wind turbines with low-temperature nodular graphite iron, using furan resin sand as the mold sand and having no risers or chills in the mold. The mold undergoes microseismic compaction and has no chills risers. The parting face of the mold is perpendicular to the ground. The molten iron in the mold is solidified evenly. Therefore, shrinkage holes and disperse shrinkages base are reduced greatly and the dregs and air are discharged easily for the base. The pouring system designed together with a reasonable pouring rate and time make the filtering system useful for blocking dregs.Type: GrantFiled: February 1, 2009Date of Patent: January 17, 2012Assignee: Jiangsu Jixin Wind Energy Technology Co., Ltd.Inventors: Yongluo Hua, Jianhong Wang, Yufang Chen, Qiang Wang, Yuebing Wu
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Publication number: 20110277952Abstract: Described herein, in the preferred embodiment, is a leonardite-based polyurethane resin binder that may be used, among other applications, as a binder in combination with foundry aggregate, e.g., sand, for molding or casting metal parts. The binders described herein comprise a humic substance, preferably leonardite, combined with a polymerizable polyol, an isocyanate, and a polymerization catalyst to make a polyurethane resin binder in situ in a foundry aggregate, such as sand. The lignite is mixed with the polymerizable polyol and dispersing agents as additives to improve the suspension quality and binder performance of the lignite-containing part of the binder components.Type: ApplicationFiled: July 22, 2011Publication date: November 17, 2011Applicant: AMCOL INTERNATIONALInventors: Jianbo Di, Joseph M. Fuqua
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Patent number: 8029614Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.Type: GrantFiled: September 2, 2009Date of Patent: October 4, 2011Assignee: Sintokogio, Ltd.Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
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Patent number: 7984750Abstract: A sand core is prepared for use in defining a surface of a cast metal article. The core is formed of sand particles bonded with a polyurethane resin, preferably a polyol moiety-containing polyurethane resin. An alkali metal hydroxide, and optionally a glycol, is mixed with precursors of the polyurethane before they are mixed with sand particles for molding and curing the core. The hydroxide and glycol may be encapsulated to prevent interference with core molding. The hydroxide and glycol is distributed in the polyurethane binder resin and used to reduce the decomposition temperature of the core binder during casting. This practice is particularly useful in removing core sand from castings of light metal, lower casting temperature metal alloys.Type: GrantFiled: November 14, 2008Date of Patent: July 26, 2011Assignee: GM Global Technology Operations LLCInventors: Thomas C. Pederson, Anil K. Sachdev
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Publication number: 20110129387Abstract: A foundry binder comprising (a) a polyol component selected from the group consisting of phenolic resins, polyether polyols, polyester polyols, aminopolyols, and mixtures thereof, and (b) a polyisocyanate component, wherein component (a) and/or (b) further comprise, as a solvent, one or more cycloalkanes.Type: ApplicationFiled: June 3, 2010Publication date: June 2, 2011Inventors: Mark Richard Stancliffe, Jörg Kroker, Xianping Wang
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Publication number: 20110108232Abstract: A binder material for binding a plurality of particles together to form a conglomerate such as a carbon-containing briquette, a sand casting core and the like is provided. The binder material can include a collagen and/or lignin and a plurality of inorganic particles. In some instances, the binder material can be used to make a composite material. The composite material can include a plurality of particles and the binder material that contains the collagen and/or lignin. The binder material affords for the plurality of particles to be bound together into a desired shape, the desired shape having desirable properties.Type: ApplicationFiled: October 6, 2010Publication date: May 12, 2011Applicant: The Penn State Research FoundationInventors: Frederick Scott Cannon, John T. Fox, He Huang, Robert C. Voigt, James C. Furness, Paul D. Paulsen, Gregory Sanders, Matthew Robert Lumadue, Allura Marie Jiles, Paul Jonathan Munson, Sridhar Komarneni, Nicole Robitaille Brown, James A. Devenne, JR.
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Patent number: 7938169Abstract: Additives to foundry sand cores are provided for reducing or eliminating surface defects called veins in metal castings, by reducing the propensity of sand mold and core aggregates to crack during metal casting. The additives generally include an iron oxide component such as magnetite and hematite and a glass component which is preferably free of lithium oxide. The additive may also optionally include an amount of carbon effective to reduce adhesion of sand particles to the casting.Type: GrantFiled: June 20, 2008Date of Patent: May 10, 2011Assignee: Prince Minerals, Inc.Inventors: Jon H. Attridge, Joshua M. Werling
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Publication number: 20110005702Abstract: The invention relates to a molding material mixture for production of molded products for the foundry industry, comprising at least one fire-resistant base molding material and a polyurethane-based binder system comprising a polyisocyanate component and a polyol component. According to the invention, the polyurethane-based binder system comprises a portion of a carboxylic acid diester of a branched alkane diol, said portion being at least 3 weight-%, and a portion of aromatic solvent of less than 10 weight-% of the binder system. A preferable carboxylic acid diester is 2,2,4-trimethyl-1,3-pentandiol-diisobutyrate.Type: ApplicationFiled: January 30, 2009Publication date: January 13, 2011Applicant: ASHLAND-SUDCHEMIE-KERNFEST GMBHInventors: Christian Priebe, Diether Koch
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Publication number: 20100319874Abstract: A bio-based binder system for use in preparing foundry molds. In a preferred embodiment, the system includes the use of a) a polyermizable hydroxyl-containing component comprising a saccharide, b) an isocyanate component, and c) a catalyst, and preferably amine catalyst, component adapted to catalyze the polymerization of a) and b), in the presence of a foundry aggregate such as sand. The system can be used in any suitable manner, including in either a cold box process or no bake process as described herein.Type: ApplicationFiled: November 14, 2008Publication date: December 23, 2010Applicant: UNIVERSITY OF NORTHERN IOWA RESEARCH FOUNDATIONInventors: Gerard R. Thiel, Shoshanna R. Coon, Mitchell Patterson, Andrew Simonson, Ian Williams, Ryan Jones
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Publication number: 20100252226Abstract: An alkaline phenolic resole resin compositions comprising (a) an aqueous basic solution of a phenolic resole resin, (b) and a polyhydric alcohol, and their use in foundry applications.Type: ApplicationFiled: March 15, 2010Publication date: October 7, 2010Inventors: Carlito G. Bangcuyo, Timothy A. Ropp, Jorg Kroker
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Patent number: 7807077Abstract: New methods and systems for manufacturing a three-dimensional form, comprising steps of providing a plurality of particulates; contacting the particulates with an activation agent; contacting particulates having the activation agent with a binder material that is activatable by the activation agent; at least partially hardening the binder for forming a layer of the three-dimensional form; and repeating these steps to form the remainder of the three-dimensional form. Following sequential application of all required layers and binder material to make the form, the unbound particles are appropriately removed (and optionally re-used), to result in the desired three-dimensional form. The invention also contemplates a novel method for preparing a form, where unbound particulates free of binder material are re-claimed.Type: GrantFiled: June 11, 2004Date of Patent: October 5, 2010Assignee: Voxeljet Technology GmbHInventors: Rainer Hochsmann, Ingo Ederer
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Publication number: 20100025005Abstract: A method of casting the base of high-power wind turbines with low-temperature nodular graphite iron, use furan resin sand as the mold sand, and there is no riser or chill in the mold. The mold undergoes microseismic compaction, has no chill and riser, and when parting the parting face is perpendicular to the ground. The molten iron solidifies evenly, which greatly reduces the shrinkage holes and disperse shrinkage, and the dregs and air are easy to be discharged. The pouring system designed for the base, together with reasonable pouring rate and time, makes the system useful in blocking the dregs. All areas of the base need to meet the standards of EN DIN12680 Level 2 or Level 3 of the UT tests.Type: ApplicationFiled: February 1, 2009Publication date: February 4, 2010Applicant: JIANGSU JIXING WIND TURBINES LIMITEDInventors: YONGLUO HUA, JIANHONG WANG, YUFANG CHEN, QIANG WANG, YUEBING WU
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Publication number: 20090314461Abstract: Additives to foundry sand cores are provided for reducing or eliminating surface defects in metal castings. The additives generally comprise an iron oxide component and a glass component which is preferably free of lithium oxide.Type: ApplicationFiled: June 20, 2008Publication date: December 24, 2009Applicant: Prince Minerals, Inc.Inventors: Jon H. Attridge, Joshua M. Werling
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Publication number: 20090236070Abstract: To provide a casting mold manufacturing apparatus using steam heating. The apparatus includes a forming die having a cavity, a resin-coated sand supply section for supplying a resin-coated sand into the cavity, a steam supply section for supplying steam into the cavity, and a steam discharge section for discharging the steam from the cavity. At least a portion of the forming die is composed of a porous material having pores with an average diameter smaller than an average particle diameter of the resin-coated sand. At least a portion of the steam is supplied into the cavity through the porous material. Since it is possible to uniformly supply the steam into the cavity, a homogeneous casting mold can be manufactured.Type: ApplicationFiled: April 27, 2007Publication date: September 24, 2009Applicants: LIGNYTE CO., LTD., MAEDA SHELL SERVICE CO., LTD.Inventors: Isamu Ide, Sadao Maeda
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Publication number: 20090211725Abstract: A molding process which comprises mixing together a particulate aggregate, plural kinds of water-soluble binders, a crosslinking agent causing crosslinking reaction with the binders, a phenol resin, and water, agitating the obtained mixture to prepare a bubbled fluid aggregate mixture, filling the aggregate mixture into a molding cavity, and solidifying the aggregate mixture through the evaporation of water from the mixture to give a mold made from the mixture.Type: ApplicationFiled: June 29, 2005Publication date: August 27, 2009Inventors: Norihiro Asano, Toshihiko Zenpo, Masaya Hotta, Kazuyuki Nishikawa
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Publication number: 20090183852Abstract: A foundry shell core includes an outer shell made of a polymerised sand and resin mixture suitable for withstanding the heat and metallostatic pressure produced by molten metal during casting, and of an inner core body made of a material suitable for being thermally dissolved before using the shell core forming an inner cavity inside the core itself that facilitates the intake of smoke and gases produced during the casting. Alternatively, the inner core body is dissolved after the solidification of the casting. The shell cores are obtained by injection with the use of a conventional core box into which the core bodies, previously obtained by a die, have been inserted.Type: ApplicationFiled: October 23, 2006Publication date: July 23, 2009Applicant: BASSI TECHNOLOGY S.R.L. UNIPERSONALEInventor: Bruno Bassi
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Publication number: 20080135721Abstract: Disclosed herein is a method comprising disposing a casting composition within a sacrificial die; wherein internal features of the sacrificial die provide a replica of a desired casting; wherein the casting composition has a viscosity of about 1 to about 1,000 Pascal-seconds at room temperature when tested at a shear rate of up to 70 seconds?1; reacting the casting composition to form a gel matrix; removing the sacrificial die; extracting a solvent from the gel matrix to form a dried gel; and firing the dried gel to form a ceramic core. Disclosed herein too is a casting composition comprising a monomer and/or a polymer; and a metal and/or ceramic powder; wherein the casting composition has a viscosity of about 1 to about 1,000 Pascal-seconds at room temperature when tested at a shear rate of up to 70 seconds?1 and a flow index of less than 0.6.Type: ApplicationFiled: December 6, 2006Publication date: June 12, 2008Applicant: GENERAL ELECTRIC COMPANYInventors: Hsin-Pang Wang, John Thomas Leman, Thomas Francis McNulty, Ching-Pang Lee
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Patent number: 7097801Abstract: The present invention involves a method of making an integrated mold product with a molding tool. The method includes introducing polymeric material in the molding tool and molding the polymeric material to define an outer layer in the mold. The outer layer has a channel formed thereon. The method further includes introducing molten metal in the channel of the outer layer when the outer layer is at about the same temperature as the molding tool and cooling the molten metal in the channel to define a metal insert in the channel of the outer layer for electrical and thermal conductivity, structural support, and electromagnetic shielding.Type: GrantFiled: July 2, 2002Date of Patent: August 29, 2006Assignee: Visteon Global Technologies, Inc.Inventors: Harvinder Singh, Donald Hanson
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Patent number: 7081487Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) an effective amount of a oxidizing agent, and (d) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.Type: GrantFiled: July 25, 2003Date of Patent: July 25, 2006Assignee: Ashland Licensing and Intellectual Property LLCInventor: H. Randall Shriver
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Patent number: 6920911Abstract: Sand mold for shaping molten metal cast into the mold. The mold includes sand, a thermally oxidizable polymer amongst the grains of the sand, and a catalyst coating on the gains for promoting the thermal oxidation and breakdown of the polymer in the course of removing the sand from the casting and/or reclaiming the sand for reuse. The catalyst coating adheres so tenaciously to the grains of sand that the sand can withstand repeated casting and sand reclamation cycles without the need to replenish the catalyst.Type: GrantFiled: November 7, 2003Date of Patent: July 26, 2005Assignee: General Motors CorporationInventors: Nicholas Edward Sargent, June-Sang Siak, Mei Cai
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Patent number: 6883587Abstract: This invention relates to polyisocyanate compositions comprising (a) polyisocyanate, and (b) a monomeric carbodiimide. The polyisocyanate compositions are particularly useful in phenolic urethane foundry binder systems. The invention also relates to foundry mixes prepared with (a) a phenolic urethane binder containing the polyisocyanate composition, and (b) a foundry aggregate, as well as foundry shapes prepared by the no-bake and cold-box processes, which are used to make metal castings.Type: GrantFiled: February 14, 2002Date of Patent: April 26, 2005Assignee: Ashland Inc.Inventors: Chia-hung Chen, Jorg Kroker
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Patent number: 6789724Abstract: An exothermic welding system uses compressible layers of disposable refractory batting or gaskets to form a weld chamber for parts to be welded. The parts to be welded are layered with the batting between a base and a crucible platen supported by a clamping fixture. The layered batting is provided with the holes intersecting the parts to be welded. The holes form the weld chamber. The crucible platen is provided with a chamber for the exothermic material which when ignited forms molten metal which flows through a tap hole into the weld chamber. When the weld is made, the fixture is opened and the batting is discarded. The invention is also the method of forming the welded connection by compressing the layered batting and the parts to be welded to form the disposable weld chamber enabling a simpler and lower cost welding system to make a wide variety of connections not requiring a large inventory of special and costly refractory mold parts.Type: GrantFiled: July 2, 2002Date of Patent: September 14, 2004Assignee: Erico International CorporationInventors: Bernard J. Cordier, Didier J. M. Quoy, Jacobus P. M. Hermans, Johannes L. L. A. van den Broek
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Patent number: 6772820Abstract: A cold-box process for preparing a foundry shape, e.g. mold or core, that uses a binder comprising a phenolic resin component and an isocyanate component, wherein the phenolic resin component comprises (a) an alkoxy-modified phenolic resole resin and (b) an oxygen-rich polar, organic solvent component, which contains a fatty acid ester.Type: GrantFiled: June 26, 2003Date of Patent: August 10, 2004Assignee: Ashland Inc.Inventors: Jean-Claude Roze, Günther Weicker, Diether Koch, Andreas Werner
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Publication number: 20040132861Abstract: A cold-box process for preparing a foundry shape, e.g. mold or core, that uses a binder comprising a phenolic resin component and an isocyanate component, wherein the phenolic resin component comprises (a) an alkoxy-modified phenolic resole resin and (b) an oxygen-rich polar, organic solvent component, which contains a fatty acid ester.Type: ApplicationFiled: September 12, 2003Publication date: July 8, 2004Applicant: Ashland Inc.Inventors: Jean-Claude Roze, Gunther Weicker, Diether Koch, Andreas Werner
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Patent number: 6710094Abstract: The present invention is directed to processes for forming styrenic polymers, and their related end uses. In particular, the present invention is directed to processes for preparing patterns for use in metal castings.Type: GrantFiled: December 17, 2002Date of Patent: March 23, 2004Assignee: StyroChem Delaware, Inc.Inventor: Fred Sonnenberg
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Patent number: 6686402Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy novolac resin; (b) preferably a bisphenol F; (c) an acrylate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.Type: GrantFiled: September 27, 2001Date of Patent: February 3, 2004Assignee: Ashland Inc.Inventors: Wayne D. Woodson, H. Randall Shriver
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Patent number: 6684936Abstract: This invention relates to erosion resistant foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) a multifunctonal acrylate; (c) a phenolic resin that is soluble in (a) and (b); and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.Type: GrantFiled: April 10, 2002Date of Patent: February 3, 2004Assignee: Ashland Inc.Inventors: Wayne D. Woodson, James J. Archibald, H. Randall Shriver
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Patent number: 6662854Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an aliphatic epoxy resin; (b) a multifunctional acrylate; and (c) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly aluminum castings.Type: GrantFiled: April 5, 2002Date of Patent: December 16, 2003Assignee: Ashland Inc.Inventors: Wayne D. Woodson, H. Randall Shriver
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Patent number: 6664310Abstract: This invention relates to hydrogenfluorides of aminosilanols and their use. The hydrogenfluorides of aminosilanols are formed by the reaction of an aqueous solution of a fluorinated acid, preferably, hydrofluoric acid, with an aminoalkoxysilane. The hydrogenfluorides of aminosilanols are particularly useful in foundry binders, most particularly no-bake and cold-box phenolic urethane foundry binders.Type: GrantFiled: April 24, 2002Date of Patent: December 16, 2003Assignee: Ashland Inc.Inventors: Chia-hung Chen, Jorg Kroker, Robert B. Fechter
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Publication number: 20030173055Abstract: This invention relates to polyisocyanate compositions comprising (a) polyisocyanate, and (b) a monomeric carbodiimide. The polyisocyanate compositions are particularly useful in phenolic urethane foundry binder systems. The invention also relates to foundry mixes prepared with (a) a phenolic urethane binder containing the polyisocyanate composition, and (b) a foundry aggregate, as well as foundry shapes prepared by the no-bake and cold-box processes, which are used to make metal castings.Type: ApplicationFiled: February 14, 2002Publication date: September 18, 2003Inventors: Chia-hung Chen, Jorg Kroker