Abstract: A composition comprising: lignin, a polyol carrier compound and an isocyanate is disclosed. The lignin being mixed with the polyol carrier compound. The polyol carrier compound is selected from the group consisting of TCPP, TECP, TMCP, TDCP, ethoxylated and propoxylated phenols, tris-chloroisopropyl phosphate, amino methyl propanol, glycerin carbonate, polyether modified polysiloxanes, bromophthalic anhydride derivatives, propanediols; bromine, chlorine and/or phosphorus based fire retardents, epoxies, glycerins, sugar, glycols, certain natural oil based polyols and ethoxylated and or propoxylated alcohols. The lignin-polyol carrier compound mixture is reacted with the isocyanate producing a foam, plastic or other material. For a thermoplastic solid the same polyol carrier compounds are used but in higher percentages of lignin.

Abstract: The present disclosure relates to novel aromatic polyester polyol compositions comprising lignin as a major reactant that is suitable for producing polyurethane rigid foams and coatings.

Abstract: Disclosed are polyurethane foam-forming compositions with a phase stable isocyanate-reactive composition that includes a halogenated olefin blowing agent that has low or no ozone depletion potential and low global warming potential. Such polyurethane foam-forming compositions are suitable for spray application to produce polyurethane foams that are believed to exhibit good fire resistance properties, low smoke generation and low or no scorch due to reduced exotherm, thereby making them particularly suitable for use, for example, as relatively thick wall and/or roof insulation.

Abstract: Provided is an inorganic binder composition for molding sand which includes a modified alkali silicate mixture, a hardening agent, a cross-linking agent and a rheology control agent. The inorganic binder composition may control hygroscopicity (deliquescence) of alkali silicate and keep strength steadily by polymerizing alkali silicate by the hardening agent and cross-linking it by the cross linking agent to form a hardened silicate coating (film) which may suppress generation of moisture.

Abstract: 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.

Abstract: 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.

Abstract: 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, thickening and dispersing agents as additives to improve the suspension quality and binder performance of the lignite-containing part of the binder components.

Abstract: 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.

Abstract: A system for use in forming polymer compositions, including as a replacement for phenolic based resin systems, for instance, in preparing foundry molds. In a preferred embodiment, the system includes the use of a) a polyermizable hydroxyl-containing component comprising a humic substance (as can be provided by lignite), b) an isocyanate component, and c) a catalyst, and preferably amine catalyst, component adapted to catalyze the polymerization of a) and b). The system is optionally used as binder system in the presence of a filler, such as, in combination with a foundry aggregate such as sand. A polymer system of this invention can be substantially free of formaldehyde or phenol, and preferably contains little or no aromatic solvents.

Abstract: Feeders for use in the foundry industry comprising (a) rice husk ash containing, based on the total amount of the constituents detectable in the rice husk ash by quantitative phase analysis by means of x-ray diffractometry (i) crystalline modifications of silicon dioxide, (ii) monoclinic feldspar and (iii) amorphous silicon dioxide, a total content of at least 70 wt. %, preferably more than 75 wt. % of (i) crystalline modifications of silicon dioxide and (ii) monoclinic feldspar, wherein, based on the total weight of the shapeable composition of the feeder, the amount of this rice husk ash is in the range of from 5 to 50 wt. %, preferably 5 to 25 wt. %, (b) cured binder, (c) optionally fibre material, (d) optionally one or more further fillers, and (e) optionally an oxidizable metal and an oxidizing agent for the oxidizable metal are described.

Abstract: 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.

Abstract: 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.

Abstract: Described herein, in a 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, first mixed with a foundry aggregate and then the humic-aggregate mixture is 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 added as a solid to the foundry aggregate, and improves the binder performance of the lignite-containing part of the binder components.

Abstract: Described herein, in a 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, first mixed with a foundry aggregate and then the humic-aggregate mixture is 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 added as a solid to the foundry aggregate, and improves the binder performance of the lignite-containing part of the binder components.

Abstract: A foundry mix composition including silica sand, unexpanded perlite ore, and a binder material. The unexpanded perlite ore is present in the foundry mix composition from about 0.5 wt % to about 5.0 wt %. Exemplary embodiments of the present invention also contemplate methods of making a sand mold/core from such a foundry mix composition.

Abstract: 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.

Abstract: A process for producing casting cores or molds from a mold material, based on mold base material and organic or inorganic binder, an additive composed of pore former, icing sugar and/or a similar carbon compound, and dye being admixed to the mold material and/or the binder.

Abstract: Disclosed is a foundry mix containing an organic salt and its use to make foundry shapes by the warm-box, hot-box, no-bake, and cold-box process, the use of these foundry shapes to make metal castings, and the metal castings prepared by the process.

Abstract: 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, thickening and dispersing agents as additives to improve the suspension quality and binder performance of the lignite-containing part of the binder components.

Abstract: 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 isocyanate, a polymerizable polyol, and a polymerization catalyst to make a polyurethane resin binder in situ in a foundry aggregate, such as sand.

Abstract: 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.

Abstract: A polyisocyanate production system is provided that can stably produce chlorine from hydrogen chloride produced secondarily while reacting stably between carbonyl chloride and polyamine and can perform an effective treatment of the hydrochloric gas produced secondarily. A hydrochloric gas control unit 32 controls a flow-rate control valve 23 to keep constant an amount of hydrogen chloride supplied from a hydrogen chloride purifying tank 4 to a hydrogen chloride oxidation reactor 6 via a second hydrochloric-gas connection line 11 to be constant, and also controls a pressure control valve 22 based on an inner pressure of the hydrogen chloride purifying tank 4 input from a pressure sensor 25 to discharge the hydrochloric gas from the hydrogen chloride purifying tank 4 to the hydrogen chloride absorbing column 5 via a first hydrochloric-gas connection line 10, so as to keep an inner pressure of the hydrogen chloride purifying tank 4 to be constant.

Abstract: A method for the production of cores and molds for casting molds, based on a base molding material and an organic or inorganic binding agent and an additive. According to the method, pre-forming substances are used in order to dispense with the use of sizing substances and to prevent the formation of ribs.

Abstract: Broadly, the invention provides for a cold-box aggregate binder typically being a mixture of phenolic or urea resin and a furanic material selected from one or more of the group consisting of 5-hydroxymethyl furfural (HMF); 2,5-furan dimethylol (FDM); 2,5-furan dicarboxylic acid (FDCA); 2,5-diformyl furan (DFF); FDCA monoalkyl ester (hemiester); FDM-ether; and HMF-ether; that cures in the presence of a catalyst gas.

Abstract: Foundry cores and molds for casting metals are prepared by forming a binder comprising a polyol, an isocyanato urethane polymer and a urethane catalyst. The binder additives and resin formulations of the invention are especially useful for casting non-ferrous metals, for example, the casting of aluminum, magnesium and other lightweight metals. The cores and molds produced for casting aluminum and other lightweight metals exhibit excellent shakeout while retaining other desirable core and mold properties.

Abstract: This invention describes the use of higher fatty acid methyl esters, i.e. of methyl monoesters of fatty acids having a carbon chain of 12 C atoms or more, for example of rapeseed oil methyl ester, as solvent for the individual or both components of polyurethane binders for molding materials used in foundry technology, the components of which comprise a phenolic resin which contains free OH groups and a polyisocyanate as a reaction participant. The fatty acid methyl esters can be the sole solvent. However, they also can be used, at least for the polyisocyanate, together with a high boiling aromatic hydrocarbon, whereby the amount of the fatty acid methyl ester should exceed the amount of the hydrocarbon, and they can be used, at least for the phenolic resin, together with a solvent of higher polarity. The use of fatty acid methyl esters entails considerable benefits.

Abstract: 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.

Abstract: This invention relates to a polyurethane-forming no-bake foundry binder comprising a (a) polyether polyol component comprising (1) a polyether polyol, (2) hydrofluoric acid, and (3) an aminoalkoxysilane, (b) a polyisocyanate component, (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.

Abstract: This invention relates to a polyurethane-forming no-bake foundry binder comprising a (a) polyol component comprising (1) a polyol selected from the group consisting of polyether polyols, aminopolyols, polyester polyols, and mixtures thereof, and (2) a hydrogenfluoride of aminosilanol, (b) a polyisocyanate component, and optionally (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.

Abstract: This invention relates to an organic foundry binder containing an alkyl resorcinol, or preferably a readily available mixture of alkyl resorcinols, and derivatives thereof. Preferably, the organic foundry binder is a furan binder. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and allowing it to cure to form a workable foundry shape. The invention also relates to the preparation of metal castings using the foundry shapes and the metal castings prepared with the foundry shapes.

Abstract: A fire-resistant composite substrate for use in making structural openings fire-resistant, the substrate containing: (a) elastically compressible particles; (b) at least one heat-activated expanding agent; (c) at least one heat-activated binder; and (d) a diisocyanate adhesive.

Abstract: This invention relates to a polyurethane-forming no-bake foundry binder comprising a (a) polyether polyol component comprising (1) a polyether polyol, (2) hydrofluoric acid, and (3) an aminoalkoxysilane, (b) a polyisocyanate component, (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.

Abstract: No-bake foundry binders that produce foundry shapes with improved hot strength are provided. The binder comprises a polyether polyol component, a polyisocyanate component and a catalyst component that promotes the trimerization of polyisocyanates to polyisocyanurates. Supplemental catalysts that promote the reaction of the isocyanate with the polyols may also be used. Foundry mixes are prepared by mixing the binder with a foundry aggregate and making foundry shapes using the no-bake process.

Abstract: Two-component binder system with reduced release of aromatic compounds during foundry operations, the system consisting of a phenol resin component and a polyisocyanate component, the phenol resin component comprising a phenol resin having at least two OH groups per molecule and the polyisocyanate component comprising a polyisocyanate having at least two isocyanate groups per molecule, wherein at least the phenol resin component contains a solvent, and wherein at least one of the phenol resin component and the polyisocyanate component comprises a solvent selected from the group consisting of alkyl silicates, alkyl silicate oligomers and mixtures thereof.

Abstract: 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 acrylated organic polyisocyanate, (c) a reactive unsaturated acrylic monomer, acrylic polymer, or mixtures thereof, and (d) an oxidizing agent comprising a hydroperoxide. 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.

Abstract: This invention relates to foundry mixes and their use in preparing foundry shapes (molds and cores) and in casting metals. The foundry mixes comprise a foundry aggregate and an organic foundry binder that contains an organic polyisocyanate and an aliphatic mercaptan. The binder systems react to form thiocarbamate polymers when mixed with sand. Preferably, a tertiary amine curing catalyst is used to promote the reaction of the organic polyisocyanate and aliphatic mercaptan.

Abstract: An embodiment of the present invention provides a method for improving the tensile strength of foundry cores and molds. More particularly, an embodiment of the present invention provides an improved binder for foundry cores and molds that include a fluoride bearing acid in combination with an inorganic silicon compound. Alternately, the improved binder may include a fluoride bearing acid in combination with a boron compound. In a preferred embodiment, a modified part 1 binder component includes a combination of hydrofluoric acid and an inorganic silicon compound.

Abstract: The subject invention relates to a foundry binder system that cures in the presence of a volatile amine curing catalyst. The binder system comprises (a) a compound containing at least two active methylene hydrogen atoms, (b) an organic polyisocyanate (c) a reactive unsaturated acrylic monomer and/or polymer, (d) an oxidizing agent, and preferably (e) an epoxy component. The foundry binders are used for making foundry mixes. The foundry mixes are used to make foundry shapes that are used to make metal castings.

Abstract: 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.

Abstract: This invention relates to polyurethane-forming foundry binder systems comprising a phenolic resin component and a polyisocyanate component, where the polyisocyanate component contains an ortho ester. The invention also relates to foundry mixes prepared from the binder and an aggregate, as well as foundry shapes prepared by the no-bake and cold-box processes. The foundry shapes are used to make metal castings.

Abstract: 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.

Abstract: This invention describes the use of higher fatty acid methyl esters, i.e. of methyl monoesters of fatty acids having a carbon chain of 12 C atoms or more, for example of rapeseed oil methyl ester, as solvent for the individual or both components of polyurethane binders for molding materials used in foundry technology, the components of which comprise a phenolic resin which contains free OH groups and a polyisocyanate as a reaction participant. The fatty acid methyl esters can be the sole solvent. However, they also can be used, at least for the polyisocyanate, together with a high boiling aromatic hydrocarbon, whereby the amount of the fatty acid methyl ester should exceed the amount of the hydrocarbon, and they can be used, at least for the phenolic resin, together with a solvent of higher polarity.The use of fatty acid methyl esters entails considerable benefits.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A lignin-polyol mixture is reacted with an isocyanate to produce a urethane material. The rate of the reaction is controlled by the sodium concentration in the lignin-polyol mixture. The lignin includes sodium and it is desirable to have the sodium at concentrations of less than 1% by weight of the lignin. Polyether and polyester polyol, are the preferred polyols in the lignin-polyol mixture.

Abstract: Particulate refractory aggregate containing elutable alkali is treated with a particulate active clay having a particle size of less than 0.5 mm in order to reduce the level of the elutable alkali. Sand recovered from spent foundry moulds and cores produced from alkaline binders can be treated to reduce its elutable alkali content and then recycled for further foundry use.

Abstract: The invention relates to foundry binder systems which contain modified polyisocyanates. The modified polyisocyanates are prepared by reacting a polyisocyanate with a triglyceride of ricinoleic acid. These modified polyisocyanates a phenolic resole resin are mixed with a foundry aggregate to form a foundry mix which is shaped and cured with an amine curing catalyst.