Phenolic, Amine, Or Ketone Condensate With Aldehyde Patents (Class 523/143)
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Patent number: 5473009Abstract: A self-hardening mold material composition comprising 100 parts by weight of molding sand, 0.1 to 6 parts by weight of a component (a), 0.1 to 4 parts by weight of a component (b), 0.05 to 2.0 parts by weight of a component (c) as SiO.sub.2, and 0.01 to 0.Type: GrantFiled: February 17, 1994Date of Patent: December 5, 1995Assignee: Nippon Polyurethane Industry Co., Ltd.Inventors: Tadashi Kimura, Osamu Ishizu, Shin Konishi
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Patent number: 5455287Abstract: This invention relates to foundry mixes which comprise a dry foundry aggregate and a polyurethane-forming foundry binder. The binder components include a polyether polyol component and an organic polyisocyanate component which is cured with a liquid tertiary amine catalyst. The foundry mixes are used to prepare foundry shapes made from foundry mixes by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non ferrous metals.Type: GrantFiled: March 7, 1994Date of Patent: October 3, 1995Assignee: Ashland Inc.Inventors: William G. Carpenter, William R. Dunnavant
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Patent number: 5447968Abstract: This invention relates to polyurethane-forming foundry binder systems which contain a nitrogen-containing aromatic compound selected from the group consisting of 2,2'-dipyridyl, 1,10-phenanthroline, and their substituted alkyl derivatives. The foundry binder systems are particularly useful for making foundry mixes used in the cold-box fabrication process for making foundry shapes. However, the binders systems can also be used to hold foundry shapes, such as molds and cores, together in an assembly.Type: GrantFiled: July 23, 1993Date of Patent: September 5, 1995Assignee: Ashland Inc.Inventors: Kenneth W. Barnett, William G. Carpenter, William R. Dunnavant, Robert B. Fechter
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Patent number: 5346942Abstract: The present invention provides a monolithic refractory with self-flowability. A monolithic refractory of the first invention of the present invention contains refractory aggregates, liquid novolak type phenol resin and an organic separation preventative. A monolithic refractory of the second invention of the present invention contains refractory aggregates and a novolak type phenol resin solution with a number-average molecular weight of not more than 600. The first invention of the present invention gives good hot flowability and prevention of sedimentation of the aggregates to the monolithic refractory. The second invention gives good hot flowability, stabilization in adhesion and prevention of warpage of the hardened body obtained. With the present invention a monolithic refractory can be suitably selected and used according to its intended use and purpose.Type: GrantFiled: March 22, 1993Date of Patent: September 13, 1994Assignee: Shinagawa Refractories Co., Ltd.Inventors: Takashi Yamamura, Ryosuke Nakamura, Hiroshi Kiriyama
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Patent number: 5338774Abstract: Polyphosphoryl chlorides are used in polyurethane-forming foundry binder systems to extend the bench life of foundry mixes prepared by mixing the binder systems with sand. The foundry mixes are particularly useful for preparing molds and cores used for making metal castings.Type: GrantFiled: July 15, 1992Date of Patent: August 16, 1994Assignee: Ashland Oil, Inc.Inventors: William R. Dunnavant, Robert B. Fechter
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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: 5198478Abstract: A binder composition for producing articles of bonded particulate material such as foundry moulds 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 pyrrolidone or an N-substituted pyrrolidone, 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 11, 1992Date of Patent: March 30, 1993Assignee: Foseco International LimitedInventors: Garry Smith, Martin Bradley
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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: 5180759Abstract: An exothermic composition comprises a particulate readily oxidizable metal such as aluminum, magnesium or silicon and an organic fluorine-containing compound, and usually an oxidizing agent for the readily oxidizable metal. The preferred organic fluorine-containing compound is polytetrafluoroethylene. The composition may also contain a binder, a particulate refractory material, refractory fibres and/or organic fibres. The composition may be used in the casting of molten metal, either in particulate form or as a preformed shape such as a sleeve or board, to cover or surround molten metal in the feeder of a casting mould or in the head or head box of an ingot mould.Type: GrantFiled: April 25, 1988Date of Patent: January 19, 1993Assignee: Foseco International LimitedInventors: Max G. Neu, Michael J. Gough
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Patent number: 5132339Abstract: Certain polyether polyols are used in polyurethane-forming binders to improve the shakeout of molds and cores, made by cold-box and no-bake processes. Such molds and cores are used to make metal castings, particularly from low melting metals such as aluminum.Type: GrantFiled: April 24, 1990Date of Patent: July 21, 1992Assignee: Ashland Oil, Inc.Inventors: William G. Carpenter, William R. Dunnavant
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Patent number: 5043365Abstract: A granular molding material with a binder comprising a phenol novolac and a polyisocyanate which hardens upon addition of amine catalysts wherein the molar ratio of phenol to formaldehyde in the novolac is 1:0.25 to 1:0.5 and has the formula ##STR1## wherein R, R' and R" are individually selected from the group consisting of hydrogen, alkyl of 1 to 12 carbon atoms, hydroxy, cycloalkyl of 3 to 12 carbon atoms and an anellated ring and X is an integer from 0 to 4 or >4 with the percent molar distribution based on X is as follows:______________________________________ when X = 0: 20-55% X = 1: 15-30% X = 2: 10-30% X = 3: 0-50% X .gtoreq. 4: 0-2.5% ______________________________________for the production of improved foundry cores and molds.Type: GrantFiled: September 14, 1989Date of Patent: August 27, 1991Assignee: Rutgerswerke AGInventors: Arno Gardziella, Alois Kwasniok, Peter Adolphs, Ralf Wetzig
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Patent number: 5043412Abstract: A raw batch composition for use in making a shaped article such as a foundry shape or refractory article is disclosed. The composition comprises a mixture of an aggregate material; a phenol formaldehyde novolak resin; a phenol formaldehyde resole resin; and an ester functional curing agent. A shaped article prepared from the composition and processes for making a refractory body or foundry article are also disclosed.Type: GrantFiled: September 1, 1989Date of Patent: August 27, 1991Assignee: Borden, Inc.Inventors: Pitchaiya Chandramouli, Raja Iyer, Calvin Johnson
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Patent number: 5021539Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.Type: GrantFiled: March 24, 1989Date of Patent: June 4, 1991Assignee: Acme Resin CorporationInventors: David R. Armbruster, Merlyn C. Pasion
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Patent number: 4946876Abstract: Certain polyester polyols are used in polyurethane-forming binders to improve the shakeout of molds and cores, made by a cold-box process, used to make low melting metal castings.Type: GrantFiled: October 31, 1988Date of Patent: August 7, 1990Assignee: Ashland Oil, Inc.Inventors: William G. Carpenter, William R. Dunnavant
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Patent number: 4852629Abstract: Certain carboxylic acids are used in polyurethane-forming binder compositions to extend the bench life of such compositions. The binder compositions are particularly useful for preparing sand castings used for making foundry parts.Type: GrantFiled: May 16, 1988Date of Patent: August 1, 1989Assignee: Ashland Oil, Inc.Inventors: Robert B. Fechter, John J. Gardikes
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Patent number: 4852636Abstract: This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.Type: GrantFiled: February 8, 1989Date of Patent: August 1, 1989Assignee: Ashland Oil, Inc.Inventor: Colleen M. Henry
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Patent number: 4814363Abstract: This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.Type: GrantFiled: January 15, 1988Date of Patent: March 21, 1989Assignee: Ashland Oil, Inc.Inventor: Colleen M. Henry
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Patent number: 4782102Abstract: A novel organofunctional silane for use in binding agent compositions employed in foundry sands and the cores and molds made therefrom. The novel organofunctional silane is characterized in that it contains at least one sterically hindered hydrocarbon group and has attached to the silicon atom a nitrogen containing group via a carbon-silicon bond.Type: GrantFiled: August 7, 1985Date of Patent: November 1, 1988Assignee: Union Carbide CorporationInventors: James G. Marsden, Herbert E. Petty, Anthony C. Vecere, Patrick Morabito
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Patent number: 4775704Abstract: A mold material for forming sandmolds for manufacturing metal castings, consisting essentially of an organic binder: 0.4-3.0 percent, a catalyst for curing the organic binder: 0.2-2.0 percent of, a ceramic binder: 0.05-2.0 percent in terms of SiO.sub.2, a catalyst for curing the ceramic binder: 0.05-2.0 percent, and foundry sand: the balance. The mold material can be formed into a sandmold which is excellent in both strength after exposure under a room temperature atmosphere and strength after pouring molten metal thereinto and requires no mold wash or a very small amount of mold wash as obtained by spraying or the like. The mold material may preferably further includes, if required, anti-infiltration fire-proof powder; 0.1-3.0 percent, a high-temperature reinforcing material: 0.1-3.0 percent, a viscosity adjuster: 0.1-2.0 percent, and/or a grannular carbon stabilizer: 0.03-0.5 percent.Type: GrantFiled: April 22, 1987Date of Patent: October 4, 1988Inventors: Teiji Nagahori, Masanori Ohshima
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Polyurethane-forming binder compositions containing certain carboxylic acids as bench life extenders
Patent number: 4760101Abstract: Certain carboxylic acids are used in polyurethane-forming binder compositions to extend the bench life of such compositions. The binder compositions are particularly useful for preparing sand castings used for making foundry parts.Type: GrantFiled: August 25, 1986Date of Patent: July 26, 1988Assignee: Ashland Oil, Inc.Inventors: Robert B. Fechter, John J. Gardikes -
Patent number: 4735973Abstract: An additive to foundry sand molding and core aggregates used to produce cores and molds which improves the quality of castings by reducing thermal expansion and gas defects. The additive comprises a composition containing from about 15% to about 95% titanium dioxide (TiO.sub.2). Preferably, the composition of the additive comprises about 2-38% silicon dioxide (SiO.sub.2), about 5-40% ferric oxide (Fe.sub.2 O.sub.3), about 15-95% titanium dioxide (TiO.sub.2), and about 2-45% aluminum oxide (Al.sub.2 O.sub.3).Type: GrantFiled: November 15, 1985Date of Patent: April 5, 1988Inventor: John J. Brander
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Patent number: 4723592Abstract: A process for preparing an alkoxy-modified phenolic resole resin useful as the polyhydroxy component of a urethane binder composition. A phenol is reacted with a molar excess of an aldehyde in the presence of an alkaline catalyst and the resulting product is further reacted with a monohydric aliphatic alcohol under acidic conditions.Type: GrantFiled: September 19, 1986Date of Patent: February 9, 1988Assignee: Acme Resin CorporationInventors: Robert A. Laitar, Eduardo Gmez
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Patent number: 4698377Abstract: Esters of alkoxy acids, particularly those of 3-alkoxypropionic acids are used as part or all of the polar solvent in solvent systems for binder compositions containing phenolic resins and polyisocyanates.Type: GrantFiled: September 26, 1986Date of Patent: October 6, 1987Assignee: Acme Resin CorporationInventor: Robert A. Laitar
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Patent number: 4692479Abstract: An adhesive paste composition containing in admixture a resin component, a hardener component, a hydrophobic filler component and a curing agent. The resin component includes a polyol having at least two hydroxyl groups and the hardener component includes a liquid polyisocyanate containing at least two isocyanate groups. The admixture may be made by mixing together a premixed resin component containing a filler and a catalyst and a premixed hardener component containing a hydrophobic filler. The filler in the resin component, the hardener component, or both may be a thixotropic agent.Type: GrantFiled: July 19, 1985Date of Patent: September 8, 1987Assignee: Ashland Oil, Inc.Inventors: James T. Schneider, Albert L. Haugse
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Patent number: 4683252Abstract: A binder containing a phenolic resin, a polyisocyanate, and an organohalophosphate and use thereof.Type: GrantFiled: February 25, 1986Date of Patent: July 28, 1987Assignee: Ashland Oil, Inc.Inventors: William R. Dunnavant, Robert B. Fechter, John J. Gardikes, Heimo J. Langer
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Patent number: 4634758Abstract: A process for preparing an alkoxy-modified phenolic resole resin useful as the polyhydroxy component of a urethane binder composition. A phenol is reacted with a molar excess of an aldehyde in the presence of an alkaline catalyst and the resulting product is further reacted with a monohydric aliphatic alcohol under acidic conditions.Type: GrantFiled: September 30, 1985Date of Patent: January 6, 1987Assignee: Acme Resin CorporationInventors: Robert A. Laitar, Eduardo Gomez
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Patent number: 4602069Abstract: A binder composition containing a phenolic resin, a polyisocyanate, a phosphorus based acid and optionally an acid halide and/or a base, and methods of making and using the same.Type: GrantFiled: April 11, 1984Date of Patent: July 22, 1986Assignee: Ashland Oil, Inc.Inventors: William R. Dunnavant, John J. Gardikes, Heimo J. Langer
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Patent number: 4590229Abstract: A binder composition containing a phenolic resin in an organic solvent, a polyisocyanate, wherein said organic solvent is substantially free from polar solvents, and methods of making and using the same.Type: GrantFiled: June 4, 1984Date of Patent: May 20, 1986Assignee: Ashland Oil, Inc.Inventor: John J. Gardikes
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Patent number: 4568728Abstract: A foundry binder for preparing shaped foundry products, said binder having improved breakdown, which binder comprises:(a) a resin component organic resin alkyd resins, furan resins, shell phenolic resins or acid setting phenolic resin and(b) a catalystic amount of a metal drier.Type: GrantFiled: July 16, 1984Date of Patent: February 4, 1986Assignee: Delta Resins & RefractoriesInventors: Jordan J. Kopac, Arek Khachaturian
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Patent number: 4546124Abstract: A foundry binder composition which provides foundry cores and molds of superior hot strength comprises a polyisocyanate, a polyhydroxy component and a catalyst. The polyhydroxy component is an alkoxy modified phenolic resole resin containing at least one alkoxy methylene group for every six phenolic nuclei in the resin.Type: GrantFiled: October 12, 1984Date of Patent: October 8, 1985Assignee: Acme Resin CorporationInventors: Robert A. Laitar, Eduardo Gomez
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Patent number: 4540724Abstract: A binder containing a phenolic resin; a polyisocyanate; a curing component, and a phosphorus halide and use thereof.Type: GrantFiled: January 30, 1984Date of Patent: September 10, 1985Assignee: Ashland Oil Inc.Inventors: William R. Dunnavant, John J. Gardikes, Heimo J. Langer
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Patent number: 4507408Abstract: This relates to a bonding agent which is used for the production of molded foundry parts and which is composed of two basic components which harden out cold in the mixture of the molded material in the presence of a catalyst under the formation of polyurethane. One basic component is a polyol in the form of a solution of a co-condensate containing an OH group consisting of phenol, aldehyde and an alkyl phenyl siloxane with a contents of at least 3% by weight in free OH groups, if applicable in mixture with a phenol aldehyde condensate containing an OH group, and the second basic component is a polyisocyanate likewise dissolved under normal conditions. Appropriately the solvent has a content in vegetable oils, preferably castor oil.Type: GrantFiled: October 4, 1983Date of Patent: March 26, 1985Assignee: Huettenes-Albertus Chemische Werke GmbHInventors: Marek A. Torbus, Aleksandar Vujevic
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Patent number: 4478269Abstract: A method and composition for forming a dry free-flowing particulate solid is disclosed which utilizes a novel binder system for bonding particles of carbon, sand and/or other solid aggregate materials. The solid, non-sticky binder system comprises furfural, a phenolic novolak resin, and a liquid amine having free hydrogens on the amine nitrogen which is capable of reacting with furfural. This system is capable of adhering to such particles while retaining the free-flowing characteristics of the particles. The method involves mixing the aggregate with the furfural-phenolic novolak resin until tacky, and adding methylene chloride to the tacky mix while continuing to mix. The mix is cooled by the rapid evaporation of the methylene chloride and quickly forms the free-flowing characteristics of a powder or granulated material.Type: GrantFiled: February 16, 1982Date of Patent: October 23, 1984Assignee: QO Chemicals, Inc.Inventor: Denis W. Akerberg
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Patent number: 4460629Abstract: The process for preparing a resin-coated casting sand by coating sand grains with a binder comprising a liquid phenolic resin component and a polyisocyanate component, the improvement of which comprises coating sand grains with an organic solvent prior to coating of the sand grains with the binder, thereby prolonging the bench life of the resulting resin-coated casting sand and enhancing the strength of a casting mold prepared from this resin-coated casting sand. Furthermore, this process enables the utilization of sand of a low grade or reclaimed sand having a high alkaline component content, that has not been used in the conventional process, and the supply of an excellent resin-coated casting sand which is capable of providing a casting mold having a high strength and has a long bench life.Type: GrantFiled: January 8, 1982Date of Patent: July 17, 1984Assignees: Toyota Jidosha Kogyo Kabushiki Kaisha, Asahi Yukizai Kogyo Kabushiki KaishaInventors: Tetsuo Haraga, Ryuji Nomura, Isao Kai, Motoyoshi Yamasaki
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Patent number: 4459374Abstract: This invention is concerned with foundry binder compositions for alkaline aggregates such as reclaimed sand, Olivia sand, alumina sand, etc., which cure at ambient temperatures. The binder composition is composed of phenolic resins, polyisocyanates and a hydrogen chloride emitting substance upon hydrolysis. Curing of this composition is by gaseous amines. The hydrogen chloride emitting substance on hydrolysis is selected from the following: ##STR1## wherein R.sub.1, R.sub.2, R.sub.3 can be selected from: Hydrogen, Chlorine, alkyl, vinyl or alkoxy, or(b) Thionyl chloride, sulfuryl chloride, acid chlorides of sulfur, such as methyl chlorosulfuric acid, ethyl chloroculfuric acid.Type: GrantFiled: April 8, 1983Date of Patent: July 10, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Toshiaki Nishimura, Toshiyuki Tachikawa
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Patent number: 4426484Abstract: The cure of resin compositions comprising a mixture of a resole type phenol aldehyde resin and a novolac type phenol formaldehyde resin is improved by employing resorcinol as all or part of the phenolic component in the novolac type resin. The resin compositions are particularly useful as binders for foundry sand.Type: GrantFiled: October 14, 1981Date of Patent: January 17, 1984Assignee: Sumitomo Durez Company, Ltd.Inventors: Yukio Saeki, Katsuyuki Tanaka
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Patent number: 4366266Abstract: A binder composition for making molded products in conjunction with an aggregate includes in admixture a resin component comprising an organic solvent solution of a non-aqueous phenolic resin, a hardener component comprising a liquid polyisocyanate containing at least two isocyanate groups, the resin component and hardener component being curable by a curing agent, and an additional component comprising an oil-soluble phenolic resin dissolved in a drying oil and partially cross-linked therewith.Type: GrantFiled: July 14, 1981Date of Patent: December 28, 1982Assignee: Valvoline Oil & Chemicals Ltd.Inventors: Tom Mitsopoulos, Satish Jhaveri, Charles Lui
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Patent number: 4358570Abstract: A binder composition for foundry sands comprises (a) a polyisocyanate compound (e.g., polymethylene polyisocyanate), (b) a polyol compound (e.g., a polyol compound having as its principal constituent a polyether polyol of being at least bifunctional), and (c) an alkylphenol and/or an alkylphenol derivative (e.g., nonylphenol). In this binder composition, the equivalent weight ratio of the isocyanate group of component (a) and the hydroxyl group of component (b) is from 0.3:1 to 3:1, and the quantity of component (c) is 3 to 150 parts by weight relative to 100 parts by weight of the sum of the quantities of components (a) and (b).Type: GrantFiled: September 16, 1980Date of Patent: November 9, 1982Assignee: Mitsubishi Petrochemical Company LimitedInventor: Takeshi Tobinaga
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Patent number: 4317896Abstract: A binder for foundry aggregate capable of being catalytically cured with a polyisocyanate and an alkaline catalyst comprising in combination, as a major portion, a butylated phenol-formaldehyde resin, a lesser amount of a resole resin and a still lesser amount of a novolac resin.Type: GrantFiled: December 10, 1980Date of Patent: March 2, 1982Assignee: International Minerals & Chemical Corp.Inventor: Melville J. Holik
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Patent number: RE34092Abstract: This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.Type: GrantFiled: February 19, 1991Date of Patent: October 6, 1992Assignee: Ashland Oil, Inc.Inventor: Colleen M. Henry
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Patent number: RE34228Abstract: Modified benzylic ether resole resins and process for their preparation. The resins are prepared by treating a phenol with a molar excess of aldehyde in the presence of a divalent metal ion catalyst at a pH below 7 followed by further reaction at a pH above 8 in the presence of an alkaline catalyst. Alkaline solutions of the resins are used as foundry binders in an ester cure process.Type: GrantFiled: March 2, 1992Date of Patent: April 20, 1993Assignee: Acme Resin Corp.Inventors: David R. Armbruster, Merlyn C. Pasion