Composition Related To Metal Foundry Molding Or Metallurgical Furnace Or Process Of Preparing Patents (Class 523/139)
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Patent number: 6194512Abstract: An aqueous phenol/formaldehyde resole resin is disclosed having improved speciation. An aqueous extended phenol/formaldehyde and polycarboxylic acid co-binder and low emissions process for making the same are also disclosed. Glass fiber products may be prepared using the co-binder.Type: GrantFiled: June 28, 1999Date of Patent: February 27, 2001Assignee: Owens Corning Fiberglas Technology, Inc.Inventors: Liang Chen, Richard Wolever
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Patent number: 6172133Abstract: The present invention relates to a specific binder composition for molding by self-hardening comprising 6.0 to 25.0% by weight of metal salts of aliphatic sulfonic acid, a specific hardener composition for molding by self-hardening comprising 0.5 to 20.0% by weight of metal salts of aromatic sulfonic acid, and a sand composition for molding by self-hardening comprising said binder composition for molding by self-hardening and/or said hardener composition for molding by self-hardening.Type: GrantFiled: December 16, 1998Date of Patent: January 9, 2001Assignee: Kao CorporationInventors: Kazuhiko Kiuchi, Masayuki Kato, Masahiko Kagitani
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Patent number: 6147138Abstract: A method for the manufacturing of parts, especially molds or cores, by a deposition technique, comprising the steps of: depositing a layer of a pourable composite material containing particles with a binder material coating, into a process area of a defined length and width fitting to the dimensions of a part to be manufactured; applying a moderating agent onto said composite material layer in a selective sub-area of said process area; inducing energy to solidify said selective sub-area, respectively the area of said process area void of said moderating agent; repeating the aforementioned steps; and separating of solidified composite material from non-solidified composite material.Type: GrantFiled: June 3, 1998Date of Patent: November 14, 2000Assignee: Generis GmbHInventors: Rainer Hochsmann, Ingo Ederer
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Patent number: 6140388Abstract: Abrasive articles comprising a cured thermosetting binder and abrasive grains. The binder is prepared with a poly-functional molecule comprising at least two functional groups selected from the group consisting of carboxyl and anhydride, and a crosslinking agent which is selected from the group consisting of a mono(hydroxyalkyl)urea comprising a single urea group, a single hydroxyl group, and at least two carbon atoms disposed between the urea group and the hydroxyl group, and 2-oxazolidone. The abrasive articles comprise bonded, nonwoven or coated abrasive articles.Type: GrantFiled: November 23, 1998Date of Patent: October 31, 2000Assignee: National Starch and Chemical Investment Holding CorporationInventors: David R. Nass, Andrew J. Kielbania, Jr., Sharon P. Lee, Steven P. Pauls, Sr.
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Patent number: 6133340Abstract: This invention relates to exothermic and/or insulating sleeves, their method of preparation, and their use. The sleeves are prepared by shaping a sleeve mix comprising (1) a sleeve composition capable of providing a sleeve, and (2) a chemical binder. The sleeves are cured in the presence of a catalyst by the cold-box or no-bake curing process. The invention also relates to a process for casting metal parts using a casting assembly where the sleeves are a component of the casting assembly. Additionally, the invention relates to the metal parts produced by the casting process.Type: GrantFiled: October 21, 1998Date of Patent: October 17, 2000Assignee: Ashland Inc.Inventor: Paulo Roberto Menon
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Patent number: 6124375Abstract: The invention relates to foundry binder systems which use modified polyisocyanates. The modified polyisocyanates are prepared by reacting a polyisocyanate with an aliphatic alcohol having one active hydrogen atom. These modified polyisocyanates, along with a phenolic resole resin, are added to a foundry aggregate to form a foundry mix which is shaped and cured with a gaseous amine curing catalyst.Type: GrantFiled: November 20, 1998Date of Patent: September 26, 2000Assignee: Ashland Inc.Inventors: Rina Singh, Laurence G. Dammann
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Patent number: 6063833Abstract: This invention relates to a solventless polyurethane no-bake foundry binder system comprising, as individual components (a) a polyol component comprising a polyether polyol, glycol, and an aromatic polyester polyol, (b) an organic polyisocyanate component, and (c) a liquid tertiary amine catalyst component. Foundry mixes are prepared by mixing the binder system with a foundry aggregate by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non-ferrous metals.Type: GrantFiled: January 8, 1999Date of Patent: May 16, 2000Assignee: Ashland Inc.Inventors: Chia-hung Chen, Ken K. Chang
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Patent number: 6046252Abstract: A binder composition of a phenolic novolac resin and a (lower) alkoxylated triazine-formaldehyde resin curing agent is disclosed. The triazine resins have sufficient carbon atoms in the alkoxy groups so as to provide a curing agent having a water solubility of less than 15%. The binder cures at high temperatures so as to provide improved flow and prolonged workability to the composition. The compositions are useful in refractory applications having a need for high temperature curing agents such as for maintenance and repair within refractory vessels by gunning/spraying, manufacture of electrodes by the Soderberg method, and for use in blast furnace tap holes.Type: GrantFiled: February 25, 1997Date of Patent: April 4, 2000Assignee: Borden Chemical, Inc.Inventor: Arthur H. Gerber
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Patent number: 6040355Abstract: A process of making sand cores and molds without the necessity of using an amine gas or sulphur dioxide gas to act as a catalyst by coating sand with a foundry resin which is capable of holding the sand in the proper shape after molding of the core or mold which foundry resin may be of a conventional construction. After the core or mold has been formed, hot air having a temperature of at least 180.degree. F. and in the range of from there to 1000.degree. F. is passed through the formed core to harden the core or mold at a rate sufficiently high to satisfy high production conditions without the necessity of toxic amines or sulphur dioxide.Type: GrantFiled: July 1, 1998Date of Patent: March 21, 2000Inventor: Kenneth R Kurple
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Patent number: 6037389Abstract: The subject invention relates to a foundry binder system which cures in the presence of a volatile amine curing catalyst comprising (a) an epoxy resin,(b) an organic polyisocyanate, (c) a reactive unsaturated acrylic monomer or polymer, and (d) an oxidizing agent. The foundry binders are used for making foundry mixes. The foundry mixes are used to make foundry shapes which are used to make metal castings.Type: GrantFiled: March 16, 1998Date of Patent: March 14, 2000Assignee: Ashland Inc.Inventors: James J. Archibald, Matthew S. Sheridan
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Patent number: 6005021Abstract: This invention relates to polyurethane-forming foundry binder systems and foundry mixes which comprise a foundry aggregate, said foundry binder system, and a liquid amine curing catalyst. The binder system comprises a polyol component containing a polyether polyol and a monomeric glycol, and an organic polyisocyanate component. The foundry mixes are used to prepare foundry shapes made from foundry mixes by a no-bake process.Type: GrantFiled: November 20, 1998Date of Patent: December 21, 1999Assignee: Ashland Inc.Inventors: Chia-hung Chen, Thomas E. Dando
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Patent number: 5962567Abstract: Two or more sand additive particles are made to adhere to each other, using a binder. The finished product consists of free-flowing particles that are composed of the additive particles bound together by the binder. These bound additive particles may then be applied to sand, such as foundry sands, where, otherwise, multiple additions of additive might need to be made. The pH of the single additive particles can be controlled and separation of the additives due to different specific gravities can be avoided. Various mixtures of different additives are disclosed. Methods of controlling particle size of additive particles, tendency to generate dust, degrade tensile strength or control thermal expansion of foundry cores or molds by using bound additive particles are also disclosed.Type: GrantFiled: October 3, 1996Date of Patent: October 5, 1999Assignee: Borden Chemical, Inc.Inventors: Michael M. Geoffrey, Robert A. Laitar
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Patent number: 5932628Abstract: The binder composition for the production of molds of the present invention comprises a binder obtained by polycondensation of polycondensable components comprising as major components furfuryl alcohol, urea, and an aldehyde. In the binder contained in the binder composition for the production of molds, the difference ?A-B! between the weight % of charged furfuryl alcohol (A) based on the weight of the binder and the weight % of unreacted furfuryl alcohol (B) based on the weight of the binder is 5.0 to 60.0. When the binder composition for the production of molds of the present invention is used, the curing of the binder is further accelerated without deteriorating the working atmosphere.Type: GrantFiled: February 19, 1997Date of Patent: August 3, 1999Assignee: Kao CorporationInventors: Kazuhiko Kiuchi, Masayuki Kato, Masuo Sawa, Shigeo Nakai
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Patent number: 5916933Abstract: Proppants comprising a particle coated with a composition comprising bisphenol-aldehyde novolak resin, a bisphenol homopolymer or mixtures including such polymers are disclosed. Foundry sands comprising a particle coated with a composition comprising bisphenol-aldehyde novolak resin, a bisphenol homopolymer or mixtures including such polymers are disclosed. Methods of making and using these proppant particles in subterranean formations or making and using these foundry sands in foundries are also disclosed.Type: GrantFiled: March 4, 1997Date of Patent: June 29, 1999Assignee: Borden Chemical, Inc.Inventors: Calvin K. Johnson, Kwok-tuen Tse
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Patent number: 5884688Abstract: This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat.Type: GrantFiled: October 26, 1995Date of Patent: March 23, 1999Assignee: Lanxide Technology Company, LPInventors: Jonathan Wayne Hinton, Alexander Lukacs, III, James Allen Jensen
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Patent number: 5880175Abstract: The subject invention relates to a foundry binder system which cures in the presence of a volatile amine curing catalyst comprising (a) an epoxy resin,(b) an organic polyisocyanate, (c) a reactive unsaturated acrylic monomer or polymer, and (d) an oxidizing agent. The foundry binders are used for making foundry mixes. The foundry mixes are used to make foundry shapes which are used to make metal castings.Type: GrantFiled: March 4, 1997Date of Patent: March 9, 1999Assignee: Ashland Inc.Inventors: James J. Archibald, Matthew S. Sheridan
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Patent number: 5859091Abstract: This invention relates to polyurethane-forming foundry binder systems and foundry mixes which comprise a foundry aggregate, said foundry binder system, and a liquid amine curing catalyst. The binder system comprises a polyol component containing a polyether polyol and a monomeric glycol, and an organic polyisocyanate component. The foundry mixes are used to prepare foundry shapes made from foundry mixes by a no-bake process.Type: GrantFiled: June 13, 1997Date of Patent: January 12, 1999Assignee: Ashland Inc.Inventors: Chia-hung Chen, Thomas E. Dando
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Patent number: 5760104Abstract: A binder solution of a phenolic novolak resin in solvent, preferably furfuryl alcohol containing at least one chemical agent such as amines containing one to five, preferably two to four, nitrogen atoms, glycerine or mixtures thereof. Preferably, the binder solution contains about 0.2 to about 1.5 weight percent water. The binder solution is for binding refractory objects, preferably those containing doloma (calcined dolomite) aggregate. Methods of mixing these ingredients and using the mixture are also disclosed. Bricks made from the doloma aggregate mixed with the binder solution show good ambient temperature green strength and enhanced modulus of rupture after curing and coking.Type: GrantFiled: July 9, 1997Date of Patent: June 2, 1998Assignee: Borden Chemical, Inc.Inventor: Arthur Harry Gerber
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Patent number: 5744532Abstract: An injection molding binder permitting formation of a molded article incapable of sustaining such defects as a crack or an expansion at the degreasing step and allowing the degreasing treatment to be completed quickly, an injection molding composition, and a method for the production of a sintered member are disclosed. The powder injection molding binder contains a polymer (I) which is obtained by polymerizing a monomer component composed of 50 to 100% by weight of a long side chain-containing monomer and 0 to 50% by weight of other polymerizable monomer. The powder injection molding composition comprises the binder, a binder auxiliary, and a powdery material capable of sintering. The method for the production of a sintered member comprises the steps of injection molding the composition, subjecting the molded mass to a degreasing treatment, and sintering the degreased molded mass.Type: GrantFiled: March 20, 1995Date of Patent: April 28, 1998Assignee: Nippon Shokubai Co. Ltd.Inventors: Yoshimitsu Kankawa, Toshiki Nikaya
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Patent number: 5698613Abstract: A chemical binder comprising: an ester-based polyol; an isocyanate; and a catalyst capable of catalyzing a reaction between the ester-based polyol and the isocyanate. Preferably, the chemical binder is used in a mouldable mixture comprising a particulate aggregate and the chemical. Such a mouldable mixture would be in, for example, a disposable foundry mould or core. A process for producing a free-standing mould and a process for cast a metal are also described.Type: GrantFiled: February 21, 1995Date of Patent: December 16, 1997Assignee: Mancuso Chemicals LimitedInventor: Satish S. Jhaveri
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Patent number: 5688857Abstract: This invention relates to polyurethane-forming cold-box binders and foundry mixes prepared with these binders. The binder comprises a polyol component and an organic polyisocyanate component. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and curing the foundry shape with a gaseous tertiary amine curing catalyst.Type: GrantFiled: April 10, 1996Date of Patent: November 18, 1997Assignee: Ashland Inc.Inventors: Chia-hung Chen, James T. Schneider
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Patent number: 5686506Abstract: A binder solution of a phenolic novolak resin in solvent, preferably furfuryl alcohol containing at least one chemical agent such as amines containing one to five, preferably two to four, nitrogen atoms, glycerine or mixtures thereof. Preferably, the binder solution contains about 0.2 to about 1.5 weight percent water. The binder solution is for binding refractory objects, preferably those containing doloma (calcined dolomite) aggregate. Methods of mixing these ingredients and using the mixture are also disclosed. Bricks made from the doloma aggregate mixed with the binder solution show good ambient temperature green strength and enhanced modulus of rupture after curing and coking.Type: GrantFiled: April 4, 1995Date of Patent: November 11, 1997Assignee: Borden Chemical, Inc.Inventor: Arthur Harry Gerber
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Patent number: 5677371Abstract: The invention relates to a water based binder for use in a slurry for investment casting. The binder includes a mixture of a colloidal silica sol and at least one latex polymer. The latex polymer is preferably an acrylic latex or a styrene butadiene polymer (or a combination of these) which reduces the processing time between dips during shell mold making for investment casting. The latex polymer further lowers a critical concentration point or gelation point of the colloidal silica sol. The binder may be used as a primary binder or a backup binder in the shell mold making process. To make the slurry, the binder is combined with at least one refractory powder, preferably a refractory powder selected from the group of: alumino-silicates, fused silica, quartz silica, alumina, zircon, and zirconia.Type: GrantFiled: June 7, 1995Date of Patent: October 14, 1997Assignee: Remet CorporationInventor: Manuel Guerra, Jr.
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Patent number: 5629362Abstract: Photon-diffusive coating compositions contain a binder and a mineral containing at least about 65%, preferably at least about 75%, and most preferably at least about 85% to 90% silica, of which at least about 60%, preferably at least about 75% to 85% is in the crystal form of cristobalite, which has been reacted with sodium hydroxide. In typical embodiments, ground Klannerite.RTM. is reacted with sodium hydroxide in an aqueous slurry by the application of heat to just below the boiling point until the pH falls to below 12, and then a latex binder is added. Preferred binders comprise a mixture of polysaccharide resin and a latex binder; the polysaccharide resin is added, the mixture is neutralized somewhat, and then the latex binder is added. The viscosity of the final composition may be adjusted by adding water. Cured coatings exhibit good spectral reflectance and are useful in a variety of applications such as coating furnace interiors.Type: GrantFiled: May 31, 1995Date of Patent: May 13, 1997Assignee: Heatshield Technologies Inc.Inventor: Paul R. Arena
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Patent number: 5629369Abstract: The invention relates to a water based binder for use in a slurry for investment casting. The binder includes a mixture of a colloidal silica sol and at least one latex polymer. The latex polymer is preferably an acrylic latex or a styrene butadiene polymer (or a combination of these) which reduces the processing time between dips during shell mold making for investment casting. The latex polymer further lowers a critical concentration point or gelation point of the colloidal silica sol. The binder may be used as a primary binder or a backup binder in the shell mold making process. To make the slurry, the binder is combined with at least one refractory powder, preferably a refractory powder selected from the group of: aluminosilicates, fused silica, quartz silica, alumina, zircon, and zirconia.Type: GrantFiled: June 7, 1995Date of Patent: May 13, 1997Inventor: Manuel Guerra, Jr.
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Patent number: 5621036Abstract: Two or more sand additive particles are made to adhere to each other, using a binder. The finished product consists of free-flowing particles that are composed of the additive particles bound together by the binder. These bound additive particles may then be applied to sand, such as foundry sands, where, otherwise, multiple additions of additive might need to be made. The pH of the single additive particles can be controlled and separation of the additives due to different specific gravities can be avoided. Various mixtures of different additives are disclosed. Methods of controlling particle size of additive particles, tendency to generate dust, degrade tensile strength or control thermal expansion of foundry cores or molds by using bound additive particles are also disclosed.Type: GrantFiled: February 21, 1995Date of Patent: April 15, 1997Assignee: Borden Chemical, Inc.Inventors: Michael M. Geoffrey, Robert A. Laitar
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Patent number: 5616631Abstract: Sand compositions containing a binder composition and a curing agent, in which the binder composition comprises (a) a binder comprising an acid-curable resin and (b) from 0.5 to 63.0% by weight, based on the binder composition, of at least one curing accelerator selected from compounds represented by formula (1): ##STR1## wherein X.sub.1, X.sub.2 each represent a hydrogen atom, a methyl group or an ethyl group;exhibit an increased curing rate to provide a casting mold having an increased initial strength.Type: GrantFiled: October 31, 1995Date of Patent: April 1, 1997Assignee: Kao CorporationInventors: Kazuhiko Kiuchi, Shigeo Nakai, Masuo Sawa, Masayuki Kato, Mitsuru Sakai, Shinya Nomura
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Patent number: 5605943Abstract: A moldable composition suitable for use as a pattern core material for investment casting. The composition comprises a water-soluble continuous phase organic material and a water-soluble fluorescing dye dispersed through the continuous phase organic material. Related disposable thermoplastic patterns and methods are also disclosed.Type: GrantFiled: October 20, 1995Date of Patent: February 25, 1997Assignee: M. Argueso & Company, Inc.Inventor: Paul Solomon
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Patent number: 5591810Abstract: Curable furan resins modified with phenolic resins for use as binders for cements and coating compositions having improved thermal stability, processes for their preparation and their use.Preparation of curable furan resins modified with phenolic resins based on condensation products of alkylidenepolyphenols of the novolak type with furfuryl alcohol or mixtures thereof with other reactive furan derivatives, furthermore curable solutions thereof in reactive organic solvents, processes for their preparation and their use as binders having improved thermal stability for preparing self-curing, chemically resistant and high-temperature-resistant cements and coating compositions.Type: GrantFiled: April 11, 1995Date of Patent: January 7, 1997Assignee: Hoechst AktiengesselschaftInventors: Wolfgang Hesse, Klaus Rauhut
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Patent number: 5491180Abstract: Sand compositions containing a binder composition and a curing agent, in which the binder composition comprises (a) a binder comprising an acid-curable resin and (b) from 0.5 to 63.0% by weight, based on the binder composition, of at least one curing accelerator selected from compounds represented by formula (1): ##STR1## wherein X.sub.1, X.sub.2 each represent a hydrogen atom, a methyl group or an ethyl group;exhibit an increased curing rate to provide a casting mold having an increased initial strength.Type: GrantFiled: August 17, 1994Date of Patent: February 13, 1996Assignee: Kao CorporationInventors: Kazuhiko Kiuchi, Shigeo Nakai, Masuo Sawa, Masayuki Kato, Mitsuru Sakai, Shinya Nomura
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Patent number: 5459178Abstract: This invention relates to foundry mixes and their uses. The foundry mixes comprise (a) a foundry aggregate, and (b) a foundry binder comprising in admixture; (1) an acetoacetate ester; (2) an .alpha., .beta. ethylenically unsaturated monomer; and (3) a liquid tertiary amine catalyst having a pK value of 12-14. The foundry mixes are used to prepare foundry shapes made from foundry mixes by a no-bake process.Type: GrantFiled: October 21, 1994Date of Patent: October 17, 1995Assignee: Ashland Inc.Inventors: Paul S. L. Chan, Satish S. Jhaveri, W. Graham Carpenter
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Patent number: 5457142Abstract: This invention relates to a hot-box foundry mix. The hot-box foundry mix comprises (a) an aggregate (b) a thermosetting resin; (c) a latent acid curing catalyst; and (d) an effective benchlife extending amount of a compound selected from the group consisting of an alkaline earth metal carbonate, an alkaline earth metal oxide, and mixtures thereof. The hot-box foundry mixes are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.Type: GrantFiled: April 13, 1993Date of Patent: October 10, 1995Assignee: Ashland Inc.Inventors: Thomas E. Dando, Gary W. Strehl
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Patent number: 5391606Abstract: Emissive compositions are described that can be applied as a coating to the surface of an investment casting mold to increase or decrease the rate of cooling of a casting within the mold. A coating that decreases the rate of cooling of an investment casting within an investment casting mold may comprise a compound having an emissivity less than the emissivity of the mold; a high temperature glass-forming material and a solvent to make a slurry. Similarly, a coating that increases the rate of cooling may comprise a compound having an emissivity greater than the emissivity of the mold; a low temperature glass-forming material and a solvent to make a slurry. Also disclosed in a method of investment casting wherein an emissive composition is applied to the investment casting mold.Type: GrantFiled: October 4, 1993Date of Patent: February 21, 1995Assignee: Nalco Chemical CompanyInventor: Ronald S. Doles
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Patent number: 5324770Abstract: The present invention comprises block copolymers of alkylene oxides, such as ethylene oxide and propylene oxide, which are further formulated with additional polymers such as poly(N-vinylpyrrolidinone), poly (vinyl alcohol), and certain low foam additives. These polymers are useful for the coating of alumina powders for use in ceramics. In aqueous media, their lower viscosities enable facile spray drying of the coated alumina powders. The coated alumina powders may be compressed under relatively low pressure into high density forms with superior unfired compressive strengths (green strength), they are surprisingly insensitive to relative humidity, are readily ejected from the mold, and finally do not have a deleterious effect upon the ultimate high temperature sintering of the formed bodies.Type: GrantFiled: June 17, 1992Date of Patent: June 28, 1994Assignee: Nalco Chemical CompanyInventor: David R. Cosper
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Patent number: 5294649Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.Type: GrantFiled: April 2, 1993Date of Patent: March 15, 1994Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5281644Abstract: There are disclosed methods and compositions for retarding the ambient temperature hardening of a phenolic resole resin alone or with an aggregate when such resin is contacted with a nitroalkane and a hardening agent such as lightburned magnesium oxide, an organic ester functional hardening agent, and mixtures of lightburned magnesium oxide and an organic ester functional hardening agent in an alkaline medium. There is also disclosed a hardener composition for phenolic resole resins wherein the hardener composition consists essentially of a solution of a nitroalkane in an organic ester functional hardening agent.Type: GrantFiled: November 4, 1992Date of Patent: January 25, 1994Assignee: Borden, Inc.Inventors: S. Raja Iyer, David R. Armbruster, Arthur H. Gerber
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Patent number: 5264535Abstract: A resin is prepared by the reaction of a phenol, an aldehyde and an aliphatic hydroxy compound containing two or more hydroxy groups per molecule in the presence of a divalent metal ion catalyst. These resins react with polyisocyanates to form polyurethanes that are useful binders for foundry cores and molds.Type: GrantFiled: November 16, 1992Date of Patent: November 23, 1993Assignee: Acme Resin Corp.Inventors: Michael M. Geoffrey, Robert A. Laitar
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Patent number: 5248707Abstract: The hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition at a pH of at least 4.5: a compound which provides an acetate, adipate, 4-aminobenzenesulfonate, 1,2,4-benzenetricarboxylate, formate, glycolate, lactate, nitrate, benzenesulfonate, naphthalenesulfonate, methanesulfonate, phenolsulfonate, succinate, sulfamate, or toluenesulfonate anion to the composition; or an acetylacetone, 2-nitrophenol, 4-nitrophenol, salicylaldehyde compound; or a mixture of said compounds.Type: GrantFiled: January 28, 1993Date of Patent: September 28, 1993Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5242957Abstract: A binder composition for producing articles of bonded particulate material such as foundry molds or cores comprises an alkaline aqueous solution of a resol phenol-aldehyde resin, an oxyanion which can form a stable complex with the resin, and a phenyl ethylene glycol ether. The binder composition has an alkali to phenol molar ratio of from 1.5:1 to 2.5:1 and the amount of alkali present in the solution is sufficient to substantially prevent stable complex formation between the resin and the oxyanion. Bonded articles are produced by passing carbon dioxide gas through articles formed from a mixture of particulate material and the binder composition so as to produce stable complex formation and curing of the resin.Type: GrantFiled: February 13, 1992Date of Patent: September 7, 1993Assignee: Foseco International LimitedInventors: Garry Smith, Martin Bradley
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Patent number: 5223554Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.Type: GrantFiled: December 23, 1992Date of Patent: June 29, 1993Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5189079Abstract: A resin is prepared by the reaction of a phenol, an aldehyde and an aliphatic hydroxy compound containing two or more hydroxy groups per molecule in the presence of a divalent metal ion catalyst. These resins react with polyisocyanates to form polyurethanes that are useful binders for foundry cores and molds.Type: GrantFiled: June 12, 1991Date of Patent: February 23, 1993Assignee: Acme Resin Corp.Inventors: Michael M. Geoffrey, Robert A. Laitar
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Patent number: 5182347Abstract: The hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition at a pH of at least 4.5: a compound which provides an acetate, adipate, 1,2,4-benzenetricarboxylate, formate, glycolate, lactate, nitrate, benzenesulfonate, naphthalenesulfonate, methanesulfonate, phenolsulfonate, succinate, sulfamate, or toluenesulfonate anion to the composition; or a mixture of said compounds.Type: GrantFiled: December 9, 1991Date of Patent: January 26, 1993Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5182346Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.Type: GrantFiled: November 21, 1990Date of Patent: January 26, 1993Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5180795Abstract: There is disclosed methods and compositions for retarding the room temperature hardening of phenolic resole resins when such resins are mixed with lightburned magnesium oxide with or without an ester functional hardening agent. Compounds which act as retarders include azelaic acid, salicylamide, sulfanilic acid, N-methylaniline, and 2,6-diethylaniline.Type: GrantFiled: May 13, 1991Date of Patent: January 19, 1993Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5179177Abstract: Retarding the hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition a compound which provides an aspartate, fluoride, bifluoride, malate, tartrate, citrate, oxalate, phosphate or phosphonate anion to the composition or a tetraalkoxy silane, a partially hydrolyzed tetraalkoxy silane, 2-, or 4-chlorophenol, or 2'-, or 4'-hydroxyacetophenone.Type: GrantFiled: August 22, 1991Date of Patent: January 12, 1993Assignee: Borden, Inc.Inventor: Arthur H. Gerber
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Patent number: 5169880Abstract: A foundry sand mold is produced by molding a granular refractory material with the use of (1) a binder comprising a silane coupling agent, a water-soluble phenolic resin and a silane compound selected from an alkyl silicate having 1 to 8 carbon atoms in the alkyl group, its lower condensate, a silicone oil and a modified silicone oil and (2) a hardening agent comprising an organic ester.Type: GrantFiled: March 7, 1991Date of Patent: December 8, 1992Assignee: Kao CorporationInventors: Akira Yoshida, Shigeo Nakai, Naoki Kyochika, Akio Mamba
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Patent number: 5132338Abstract: A powder mixture used for powder metallurgy containing a metal powder as a substrate, in which a copolymer comprising the following monomer ingredients as a binder is blended:______________________________________ acrylic acid ester: 20 to 70 parts by weight methacrylic acid ester: 80 to 30 parts by weight polymerizable unsaturated acid: 0.5 to 9 parts by weight based on 100 parts by weight of the sum for the acrylic ester and the methacrylic acid ester, ______________________________________as a binder is blended therewith.The powder mixture used for powder metallurgy is manufactured by mixing the starting powdery metal material with the starting powdery material for the physical property improving ingredient, adding the solution of the binder thereto and then applying stirring and drying.Graphite segregation can be prevented without de-naturing or reducing flow rate of the substrate metal and dusting upon handling can be suppressed.Type: GrantFiled: February 9, 1990Date of Patent: July 21, 1992Assignee: Kabushiki Kaisha Kobe Seiko ShoInventors: Takehiko Hayami, Hitoshi Sakuma, Jiro Chosokabe
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Patent number: 5132778Abstract: Briefly, according to the invention, a transfer molding compound is made from an epoxide resin, a cyanate ester, and a catalyst. The molding compound is used to encapsulate semiconductor devices to fabricate individual packages or to encapsulate devices mounted directly on a circuit carrying substrate.Type: GrantFiled: September 17, 1990Date of Patent: July 21, 1992Assignee: Motorola, Inc.Inventors: Frank J. Juskey, Robert W. Pennisi, Marc V. Papageorge
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Patent number: 5055350Abstract: A railroad cross-tie made from sand and recycled thermoplastic containers. To practice the invention the containers made of many thermoplastic materials are granulated and mixed together. The labels and small amounts of residue from the original contents remain on the containers. Sand is dried and coated with an adhesive substance. The coated sand and recycled granulated thermoplastic plastics are mixed and heated in a compression mold to form the railroad cross-tie.Type: GrantFiled: August 6, 1990Date of Patent: October 8, 1991Inventor: Charles W. Neefe
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Patent number: 4997860Abstract: A sand casting caking agent contains an acid-curable resin and an organosilicon compound of the general formula (I): ##STR1## in which R.sup.1 is hydrogen or an alkyl having from 1 to 6 carbon atoms, R is a substituted or nonsubstituted monovalent hydrocarbon group, Y is an alkoxy group having from 1 to 6 carbon atoms, n is an integer of from 1 to 6 and m is either 0 or 1. Casting molds containing the agent of the present invention exhibit superior moisture resistance.Type: GrantFiled: October 11, 1989Date of Patent: March 5, 1991Assignee: Toshiba Silicone Co., Ltd.Inventor: Keiji Kabeta