Phenolic Or Amine Or Ketone Condensate With Aldehyde Patents (Class 523/145)
  • Patent number: 10696600
    Abstract: A method for producing a component includes a) providing at least two preforms each made of a carbon composite material, b) joining the at least two preforms at least at one respective connecting surface to form a composite, in which a joining compound is introduced between the joining surfaces of the preforms and then cured and the joining compound contains silicon carbide and at least one polymer adhesive, and c) siliconizing the composite to form the component. A component, such as an optical component produced thereby, is also provided.
    Type: Grant
    Filed: April 26, 2017
    Date of Patent: June 30, 2020
    Assignee: SGL Carbon SE
    Inventors: Peter Polster, Andreas Kienzle, Thomas Putz, Albin Von Ganski, Blasius Hell, Alfred Haeusler
  • Patent number: 10138358
    Abstract: The present invention provides moldable compositions that are capable of drying and hardening if left in open air at room temperature for a period of time. Embodiments of the moldable compositions comprise water, at least one polar polymeric resin (e.g., polyvinyl alcohol), at least one thickening agent (e.g., boric acid, borate salt, or hydrate of a borate salt), at least one humectant (e.g., glycerin, propylene glycol, etc.), at least one filler (e.g., corn starch, tapioca, or arrowroot), optionally at least one releasing agent (e.g., mineral oil) and optionally at least one additive.
    Type: Grant
    Filed: August 26, 2016
    Date of Patent: November 27, 2018
    Assignee: CRAYOLA LLC
    Inventors: Cindy Nguyen, Michael G. Moskal, David Rowan, Michael L. Spera, James Broe Fitzpatrick
  • Patent number: 9834653
    Abstract: The invention relates to a method of producing monodisperse amidomethylated vinylaromatic bead polymers, to ion exchangers prepared from these monodisperse amidomethylated vinylaromatic bead polymers by alkaline hydrolysis, to the method of using said monodisperse amidomethylated vinylaromatic bead polymers in the manufacture of ion exchangers and chelating resins, and also to the method of using these ion exchangers in the removal of heavy metals and noble metals from aqueous solutions or gases.
    Type: Grant
    Filed: August 8, 2014
    Date of Patent: December 5, 2017
    Assignee: LANXESS DEUTSCHLAND GMBH
    Inventors: Reinhold Klipper, Wolfgang Zarges, Olaf Halle, Michael Schelhaas
  • Patent number: 9458349
    Abstract: A phenol-formaldehyde novolac resin having a low concentration of free phenol prepared by distilling residual phenol from a molten novolac resin and replacing at least a portion of the phenol with a solvent having a volatility equal to or less than phenol. Such modified novolac resins are suitable for the production of resin coated molding sands for shell molding and sand cores, as well as for the production of resin coated proppants for use in oil and gas recovery operations.
    Type: Grant
    Filed: May 11, 2007
    Date of Patent: October 4, 2016
    Assignee: Georgia-Pacific Chemicals LLC
    Inventors: Richard Rediger, Edward Lucas
  • Publication number: 20150010949
    Abstract: The present invention relates to an aqueous carbohydrate based binder composition, comprising a carbohydrate component and an amine component, wherein the carbohydrate component comprises one or more pentose sugars, as well as to a method of its production.
    Type: Application
    Filed: September 2, 2012
    Publication date: January 8, 2015
    Applicant: Knauf Insulation
    Inventors: Roger Jackson, Carl Hampson, James Robinson, Benedicte Pacorel
  • Patent number: 8919421
    Abstract: A method for producing cores and molds for the foundry industry utilizing a flowable fire-resistant primary molding material. The method includes an acid applied to the flowable fire resistant primary molding material to obtain an acid-coated fire-resistant primary molding material. A binder that can be cured by acid is applied to the acid-coated fire resistant primary molding material to obtain a fire-resistant primary molding material coated with a binder. The fire-resistant primary molding material coated with a binder is then molded into a molded body, and-the molded body is cured. The acid used is a mixture of methane sulfonic acid and at least one sulfur-free acid. The casting molds can be produced having reduced emission of harmful compounds during casting.
    Type: Grant
    Filed: May 22, 2009
    Date of Patent: December 30, 2014
    Assignee: ASK Chemicals GmbH
    Inventors: Marcus Frohn, Diether Koch, Antoni Gieniec
  • Patent number: 8813830
    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.
    Type: Grant
    Filed: January 30, 2009
    Date of Patent: August 26, 2014
    Assignee: ASK Chemicals GmbH
    Inventors: Christian Priebe, Diether Koch
  • Patent number: 8778495
    Abstract: A phenol-formaldehyde novolac resin having a low concentration of free phenol prepared by distilling residual phenol from a molten novolac resin and replacing at least a portion of the phenol with a solvent having a volatility equal to or less than phenol. Such modified novolac resins are suitable for the production of resin coated molding sands for shell molding and sand cores, as well as for the production of resin coated proppants for use in oil and gas recovery operations.
    Type: Grant
    Filed: August 1, 2012
    Date of Patent: July 15, 2014
    Assignee: Gerogia-Pacific Chemicals LLC
    Inventors: Richard A. Rediger, Edward Lucas
  • Publication number: 20140187667
    Abstract: Provided are a phenolic resin composition for shell molding that has low thermal expansion properties and high flexibility, a resin coated sand for shell molding obtained by using the same, and a shell mold formed of the same. The phenolic resin composition for shell molding that is capable of exhibiting advantageous mold characteristic is obtained by a combination of a phenolic resin that is obtained by a reaction of a phenol, a naphthol, and an aldehyde, and a fatty acid amide.
    Type: Application
    Filed: March 5, 2014
    Publication date: July 3, 2014
    Applicant: Asahi Organic Chemicals Industry Co., Ltd.
    Inventors: Keiichi MORI, Tomohiro TAKAMA
  • Patent number: 8754147
    Abstract: A formulation and method of use for eliminating the use of hexa in shell sand encapsulation is disclosed. The composition of matter consists of standard novalac resins with the hexa component replaced by solid granular resole or curing agent. The preferred formulation and method of compounding is given. Trace elements of ammonia, phenol and the like are further reduced by the addition of a preferred 50:50 mix of an ammonia buffer and masking agent. The preferred compounds for the ammonia buffer and masking agent mix are given.
    Type: Grant
    Filed: July 8, 2010
    Date of Patent: June 17, 2014
    Assignee: Fairmount Minerals, Ltd.
    Inventors: Kelley J. Kerns, Robert H. Mizwicki, Ryan Schwark
  • Patent number: 8436073
    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.
    Type: Grant
    Filed: July 22, 2011
    Date of Patent: May 7, 2013
    Assignee: Amcol International
    Inventors: Jianbo Di, Joseph M. Fuqua
  • Patent number: 8349752
    Abstract: The present invention provides a plate brick having a low amount of generation of smoke and a gas with a pungent odor during use, and exhibiting high durability. A plate brick of the present invention is obtained by: adding an organic binder to a refractory raw material mixture containing 0.5 to 20 mass % of aluminum and/or aluminum alloy; kneading the mixture with the organic binder; forming the kneaded mixture into a shaped body; and subjecting the shaped body to a heat treatment at a temperature of 400 to 1000° C., wherein the plate brick is obtained without being impregnated with a carbon-containing liquid material comprising tar or pitch, after the heat treatment. The plate brick has a compressive strength of 180 MPa or more, and a weight-increasing rate of 1% or less as measured in a hydration test using an autoclave.
    Type: Grant
    Filed: March 25, 2009
    Date of Patent: January 8, 2013
    Assignee: Krosakiharima Corporation
    Inventors: Yasuaki Shin, Kazuo Ito, Michihiko Ichimaru, Tamotsu Wakita, Masamichi Asai
  • Patent number: 8148463
    Abstract: This invention relates to alkaline resol phenol-aldehyde binder compositions and their use in the production of articles of bonded particulate material such as foundry moulds, foundry cores, or feeders.
    Type: Grant
    Filed: December 8, 2008
    Date of Patent: April 3, 2012
    Assignee: Huttenes-Albertus Chemische Werke GmbH
    Inventors: Frank Lenzen, Gerard Ladegourdie
  • Patent number: 8133933
    Abstract: Phenolic resin binder systems for sand molds, used in metal casting, which improve the quality of thermally reclaimed sand, are described. The substantial or complete elimination of calcium compounds (e.g., calcium stearate and calcium hydroxide, conventionally employed as a mold lubricant and a resin curing catalyst, respectively) allows the thermally reclaimed sand to be reused over multiple thermal reclamation cycles without the adverse effects previously encountered.
    Type: Grant
    Filed: August 11, 2006
    Date of Patent: March 13, 2012
    Assignee: Georgia-Pacific Chemicals LLC
    Inventors: Richard Rediger, Edward Lucas
  • Publication number: 20120029113
    Abstract: Provided are a phenolic resin composition for shell molding that has low thermal expansion properties and high flexibility, a resin coated sand for shell molding obtained by using the same, and a shell mold formed of the same. The phenolic resin composition for shell molding that is capable of exhibiting advantageous mold characteristic is obtained by a combination of a phenolic resin that is obtained by a reaction of a phenol, a naphthol, and an aldehyde, and a fatty acid amide.
    Type: Application
    Filed: October 11, 2011
    Publication date: February 2, 2012
    Applicant: Asahi Organic Chemicals Industry Co., Ltd.
    Inventors: Keiichi Mori, Tomohiro Takama
  • Patent number: 7984750
    Abstract: A sand core is prepared for use in defining a surface of a cast metal article. The core is formed of sand particles bonded with a polyurethane resin, preferably a polyol moiety-containing polyurethane resin. An alkali metal hydroxide, and optionally a glycol, is mixed with precursors of the polyurethane before they are mixed with sand particles for molding and curing the core. The hydroxide and glycol may be encapsulated to prevent interference with core molding. The hydroxide and glycol is distributed in the polyurethane binder resin and used to reduce the decomposition temperature of the core binder during casting. This practice is particularly useful in removing core sand from castings of light metal, lower casting temperature metal alloys.
    Type: Grant
    Filed: November 14, 2008
    Date of Patent: July 26, 2011
    Assignee: GM Global Technology Operations LLC
    Inventors: Thomas C. Pederson, Anil K. Sachdev
  • Patent number: 7928151
    Abstract: A resin composition for a shell mold which reduces smoke generation upon molding of a casting mold and maintains a crumbility and a casting mold strength of a phenolic resin, and resin coated sand by the use thereof are provided. The resin composition for the shell mold includes the phenolic resin and an aromatic condensed phosphate ester. The phenolic resin is used as a binder of the resin coated sand used for producing a main mold and a core for shell mold casting of cast iron, cast steel, aluminum, and the like. The aromatic condensed phosphate ester is very effective as a crumbling agent for improving the crumbility of the casting mold after casting.
    Type: Grant
    Filed: December 11, 2006
    Date of Patent: April 19, 2011
    Assignee: Hitachi Chemical Company, Ltd.
    Inventors: Daiki Oniyanagi, Masaru Wada, Yoshirou Oowada, Tetsurou Saikawa
  • Patent number: 7919179
    Abstract: To provide resin-coated sand for a multilayer mold in which the consolidation strength of the casting mold obtained by using it and gas permeability thereof are improved at the same time, the amount of occurrence of pyrolytic products (tar, soot and the like) derived from organic substances is effectively inhibited, when molding is performed using such a casting mold, and further, the casting mold after molding can exhibit excellent collapsibility. Disclosed is resin-coated sand for a multilayer mold, in which surfaces of refractory particles are coated with a binder composition containing a phenolic novolak resin having an ortho/para bond ratio of methylene groups of 1.5 or more and an aromatic amine as indispensable constituents, and the grain fineness number is from 80 to 150.
    Type: Grant
    Filed: August 13, 2007
    Date of Patent: April 5, 2011
    Assignees: Asahi Organic Chemicals Industry Co., Ltd., Honda Motor Co., Ltd.
    Inventors: Hiroshi Furusawa, Masanori Totsuka, Naohisa Shibata
  • Publication number: 20100286306
    Abstract: A formulation and method of use for eliminating the use of hexa in shell sand encapsulation is disclosed. The composition of matter consists of standard novalac resins with the hexa component replaced by solid granular resole or curing agent. The preferred formulation and method of compounding is given. Trace elements of ammonia, phenol and the like are further reduced by the addition of a preferred 50:50 mix of an ammonia buffer and masking agent. The preferred compounds for the ammonia buffer and masking agent mix are given.
    Type: Application
    Filed: July 8, 2010
    Publication date: November 11, 2010
    Applicant: FAIRMOUNT MINERALS, INC.
    Inventors: Kelley J. Kerns, Robert H. Mizwicki, Ryan Schwark
  • Publication number: 20100252226
    Abstract: An alkaline phenolic resole resin compositions comprising (a) an aqueous basic solution of a phenolic resole resin, (b) and a polyhydric alcohol, and their use in foundry applications.
    Type: Application
    Filed: March 15, 2010
    Publication date: October 7, 2010
    Inventors: Carlito G. Bangcuyo, Timothy A. Ropp, Jorg Kroker
  • Patent number: 7717994
    Abstract: The invention relates to coating material comprising a water-soluble salt as a filler. Such materials are especially suitable as core washes for salt cores for using in foundry technology.
    Type: Grant
    Filed: February 10, 2004
    Date of Patent: May 18, 2010
    Assignee: Ashland-Sudchemie-Kernfest GmbH
    Inventors: Herbert Pitamitz, Gernot Lederer
  • Patent number: 7579075
    Abstract: It is an object of the present invention to provide a phenolic novolak resin for a shell mold which is capable of simultaneously solving a problem of gas defect caused by a tar generated at the time of casting and a problem of a casting defect represented by veining. As the phenolic novolak resin in RCS for the shell mold, there is used a copolycondensation resin-type phenolic novolak resin obtained by reacting a phenol and an alkylphenol, with at least one of aldehydes, wherein a ratio of an ortho-bond to a para-bond of a methylene group in the phenolic novolak resin is not less than 1.5, and a fire-resisitant particle is coated with this resin.
    Type: Grant
    Filed: February 29, 2008
    Date of Patent: August 25, 2009
    Assignee: Asahi Organic Chemicals Industry Co., Ltd.
    Inventor: Hiroshi Furusawa
  • Patent number: 7407994
    Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) an acrylate; (c) an alkyl ester of a fatty acid, wherein the alkyl group of the ester is an aliphatic hydrocarbon having from 4 to 8 carbon atoms, preferably butyl tallate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: September 19, 2006
    Date of Patent: August 5, 2008
    Assignee: Ashland Licensing and Intellectual Property LLC
    Inventors: Jorg Kroker, H. Randall Shriver
  • Publication number: 20080171205
    Abstract: It is an object of the present invention to provide a phenolic novolak resin for a shell mold which is capable of simultaneously solving a problem of gas defect caused by a tar generated at the time of casting and a problem of a casting defect represented by veining. As the phenolic novolak resin in RCS for the shell mold, there is used a copolycondensation resin-type phenolic novolak resin obtained by reacting a phenol and an alkylphenol, with at least one of aldehydes, wherein a ratio of an ortho-bond to a para-bond of a methylene group in the phenolic novolak resin is not less than 1.5, and a fire-resisitant particle is coated with this resin.
    Type: Application
    Filed: February 29, 2008
    Publication date: July 17, 2008
    Applicant: Asahi Organic Chemicals Industry Co., Ltd.
    Inventor: Hiroshi FURUSAWA
  • Publication number: 20070270524
    Abstract: A formulation and method of use for reducing or eliminating the odor by-product in shell sand is disclosed. The composition of matter consist of a preferred 50:50 combination of an organic buffer solution and a masking agent added at a suitable stage in the encapsulation process for shell sand. The method use and the formulation are described.
    Type: Application
    Filed: December 27, 2006
    Publication date: November 22, 2007
    Inventors: Kelley J. Kerns, Robert H. Mizwicki, Ryan Schwark
  • Patent number: 7270879
    Abstract: Disclosed herein is a particle comprising a particulate substrate; and a thermoplastic elastomer present on or in the substrate as an amount sufficient to improve the dust suppression of the particle above that which would occur if the thermoplastic elastomer was absent. Disclosed herein is a particle comprising a particulate substrate; and a thermoplastic elastomer, wherein the particle has a compressive strength retention of greater than about 50% as measured by a UCS test and a turbidity of about 10 to 200 NTU after a one hour ball mill test.
    Type: Grant
    Filed: April 15, 2004
    Date of Patent: September 18, 2007
    Assignee: Hexion Specialty Chemicals, Inc.
    Inventor: Avis Lloyd McCrary
  • Patent number: 7129283
    Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) a fluorinated acid, preferably hydrofluoric acid; (d) an effective amount of a oxidizing agent; and (e) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: October 31, 2006
    Assignee: Ashland Licensing and Intellectual Property LLC
    Inventors: Xianping Wang, H. Randall Shriver, Jorg Kroker
  • Patent number: 7122583
    Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) an acrylate; (c) an alkyl ester of a fatty acid, wherein the alkyl group of the ester is an aliphatic hydrocarbon having from 4 to 8 carbon atoms, preferably butyl tallate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: October 17, 2006
    Assignee: Ashland Licensing and Intellectual Property LLC
    Inventors: Jorg Kroker, H. Randall Shriver
  • Patent number: 7081487
    Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) an effective amount of a oxidizing agent, and (d) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: July 25, 2006
    Assignee: Ashland Licensing and Intellectual Property LLC
    Inventor: H. Randall Shriver
  • Patent number: 7019047
    Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an alkyl silicate; (c) an ester of a fatty acid, (d) an effective amount of a oxidizing agent, and (e) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: March 28, 2006
    Assignee: Ashland Licensing and Intellectual Property LLC
    Inventors: H. Randall Shriver, Xianping Wang, Jorg Kroker
  • Patent number: 6818707
    Abstract: A binder composition comprising a blend of a crystalline phenolic compound having two or more hydroxyphenyl groups and a thermosetting spray dried phenolic resole resin is disclosed. The binder together with a filler is particularly useful in the preparation of molding compounds.
    Type: Grant
    Filed: January 8, 2002
    Date of Patent: November 16, 2004
    Assignee: Borden Chemical, Inc.
    Inventor: Wayne R. Walisser
  • Patent number: 6772820
    Abstract: A cold-box process for preparing a foundry shape, e.g. mold or core, that uses a binder comprising a phenolic resin component and an isocyanate component, wherein the phenolic resin component comprises (a) an alkoxy-modified phenolic resole resin and (b) an oxygen-rich polar, organic solvent component, which contains a fatty acid ester.
    Type: Grant
    Filed: June 26, 2003
    Date of Patent: August 10, 2004
    Assignee: Ashland Inc.
    Inventors: Jean-Claude Roze, Günther Weicker, Diether Koch, Andreas Werner
  • Patent number: 6710101
    Abstract: Binder compositions of the present invention are useful in refractory and foundry applications. The compositions include an aggregate, a liquid resole resin, and a magnesium hardening agent. The compositions are workable and exhibit high compressive strengths in a short period of time. Additionally, the compositions have a low free phenol content and require a reduced resin content as compared to currently known compositions. The compositions reduce the cost to produce useful binders by eliminating the requirement for ester curing in addition to requiring reduced amounts of resin to obtain adequate compressive strength.
    Type: Grant
    Filed: January 15, 2003
    Date of Patent: March 23, 2004
    Assignee: Borden Chemical Inc.
    Inventor: Jimmy Pingao Chen
  • Publication number: 20040029999
    Abstract: The invention relates to a binder mixture based on a pulverulent mix with non-thermoreactive phenolic resin and one or more thermoreactive condensation products, from the group consisting of phenolic resins, amino resins and epoxy resins, and a powder coating material or recycled powder coating material. The mixture can be used as a binder for textile nonwovens, moulding compounds, refractory materials, abrasive materials and friction materials, and also in the foundry industry.
    Type: Application
    Filed: November 12, 2002
    Publication date: February 12, 2004
    Inventors: Franz Josef Muller, Vito Arbia, Bernd Wellhaus
  • Patent number: 6686402
    Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy novolac resin; (b) preferably a bisphenol F; (c) an acrylate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.
    Type: Grant
    Filed: September 27, 2001
    Date of Patent: February 3, 2004
    Assignee: Ashland Inc.
    Inventors: Wayne D. Woodson, H. Randall Shriver
  • Patent number: 6684936
    Abstract: This invention relates to erosion resistant foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) a multifunctonal acrylate; (c) a phenolic resin that is soluble in (a) and (b); and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings.
    Type: Grant
    Filed: April 10, 2002
    Date of Patent: February 3, 2004
    Assignee: Ashland Inc.
    Inventors: Wayne D. Woodson, James J. Archibald, H. Randall Shriver
  • Patent number: 6662854
    Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an aliphatic epoxy resin; (b) a multifunctional acrylate; and (c) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly aluminum castings.
    Type: Grant
    Filed: April 5, 2002
    Date of Patent: December 16, 2003
    Assignee: Ashland Inc.
    Inventors: Wayne D. Woodson, H. Randall Shriver
  • Patent number: 6632527
    Abstract: Composite particles made of a binder and filler material are provided for use in subterranean formations. The filler is finely divided mineral and optional fiber. The particles are proppants useful to prop open subterranean formation fractures. The particles are also useful for water filtration and artificial turf for sports fields. Methods of making the composite particles are also disclosed.
    Type: Grant
    Filed: November 30, 1999
    Date of Patent: October 14, 2003
    Assignee: Borden Chemical, Inc.
    Inventors: Robert R. McDaniel, Johannes A. Geraedts
  • Patent number: 6604567
    Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) an acrylate; (c) an alkyl silicate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: February 14, 2002
    Date of Patent: August 12, 2003
    Assignee: Ashland Inc.
    Inventors: Wayne D. Woodson, H. Randall Shriver
  • Patent number: 6593397
    Abstract: This invention relates to furan no-bake foundry binders comprising (a) furfuryl alcohol and/or a reactive furan resin, (b) an activator selected from the group consisting of resorcinol, resorcinol pitch, and bisphenol A tar (c) a bisphenol compound (d) a polyol selected from the group consisting of polyester polyols, polyether polyols, and mixtures thereof, and preferably (e) a silane. The binders are cured in the presence of the furan curing catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.
    Type: Grant
    Filed: September 10, 2002
    Date of Patent: July 15, 2003
    Assignee: Ashland Inc.
    Inventor: Ken K. Chang
  • Patent number: 6569918
    Abstract: A polymer composition that can be used to cure a novolac resin at a lower temperature than conventional curing agents and with reduced emission of volatile compounds is disclosed. The curing agent composition is prepared by mixing and reacting in aqueous solution a phenolic monomer and an aldehyde in the presence of a basic catalyst to form an intermediate resin, and reacting the intermediate resin with an amine to form the curing agent. The aldehyde to phenolic monomer molar ratio in the reaction should be at least about 1.0:1. The preferred amine is hexamethylenetetramine, and it is preferred that the hexamethylenetetramine to phenolic monomer molar ratio is at least about 0.12:1. The curing agent releases minimal volatile compounds when used to cure novolac resins, and unlike conventional resole curing agents, has an indefinite shelf life in both the pure form and when blended with a novolac resin.
    Type: Grant
    Filed: February 4, 2000
    Date of Patent: May 27, 2003
    Assignee: Plastics Engineering Company
    Inventors: Phillip A. Waitkus, Theodore N. Morrison
  • Patent number: 6559203
    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.
    Type: Grant
    Filed: February 13, 2002
    Date of Patent: May 6, 2003
    Assignee: Ashland Inc.
    Inventors: David A. Hutchings, Heimo J. Langer, Ken K. Chang, Thomas E. Dando
  • Patent number: 6554051
    Abstract: A method of preparing foundry shapes, e.g. molds and cores, by mixing a foundry aggregate with a foundry binder, shaping the mixture in a pattern, curing the mixture, and removing the mixture from the pattern. The foundry binder is a phenolic urethane binder that utilizes a phenolic resin prepared by reacting a phenol, an aldehyde, bisphenol-A-tar, and a divalent metal catalyst.
    Type: Grant
    Filed: July 10, 2000
    Date of Patent: April 29, 2003
    Inventors: Andreas Werner, Diether Koch
  • Patent number: 6479567
    Abstract: This invention relates to furan no-bake foundry binders comprising (a) furfuryl alcohol and/or a reactive furan resin, (b) an activator selected from the group consisting of resorcinol, resorcinol pitch, and bisphenol A tar (c) a bisphenol compound (d) a polyol selected from the group consisting of polyester polyols, polyether polyols, and mixtures thereof, and preferably (e) a silane. The binders are cured in the presence of the furan curing catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.
    Type: Grant
    Filed: March 3, 2000
    Date of Patent: November 12, 2002
    Assignee: Ashland Inc.
    Inventor: Ken K. Chang
  • Patent number: 6429236
    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 Part I component comprising (1) a phenolic resin component, and (2) a free radical initiator, and a Part II component comprising (1) a polyisocyanate, and (2) a multifunctional acrylate. 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.
    Type: Grant
    Filed: May 23, 2000
    Date of Patent: August 6, 2002
    Assignee: Ashland Inc.
    Inventors: Gary M. Carlson, Robert B. Fechter, Edward G. Toplikar, D. Greg Hendershot
  • Patent number: 6426374
    Abstract: This invention relates to foundry binder compositions that contain a divalent sulfur compound, and/or foundry mixes where the aggregate contains a divalent sulfur compound. The foundry binders and foundry mixes are used to make foundry shapes, e.g. molds and cores. The presence of sulfur in the foundry shape facilitates the removal of foundry shapes (particularly internal cores) from the metal casting which is made by pouring molten metal into a casting assembly in which the foundry shapes are arranged. The invention also relates to a method of preparing foundry shapes, the shapes prepared, a method of making a metal casting, and metal castings by this process.
    Type: Grant
    Filed: July 28, 2000
    Date of Patent: July 30, 2002
    Assignee: Ashland Inc.
    Inventor: Michael J. Skoglund
  • Patent number: 6406789
    Abstract: Composite particles made of a resin and filler material are provided for use in subterranean formations. The filler is finely divided mineral and optional fiber. The particles are proppants useful to prop open subterranean formation fractures. The particles are also useful for water filtration. Methods of making the composite particles are also disclosed.
    Type: Grant
    Filed: May 22, 2000
    Date of Patent: June 18, 2002
    Assignee: Borden Chemical, Inc.
    Inventors: Robert R. McDaniel, Johannes A. Geraedts
  • Patent number: 6232368
    Abstract: An embodiment of the present invention provides a method for improving the tensile strength of foundry cores and molds over what may be conventionally achieved. The use of acidic methylene compounds in binder compositions which include strongly alkaline phenolic resoles results in an ester curable binder that may be used to make foundry cores and molds having significantly greater tensile strengths than are achieved with prior art binders. An embodiment of the present invention provides a composition which includes a phenolic resole having a pH ranging from about 10.5 to about 13.5 and an acidic methylene compound.
    Type: Grant
    Filed: October 12, 1999
    Date of Patent: May 15, 2001
    Assignee: Borden Chemical, Inc.
    Inventor: Kenneth B. White
  • Patent number: 6172133
    Abstract: 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: Grant
    Filed: December 16, 1998
    Date of Patent: January 9, 2001
    Assignee: Kao Corporation
    Inventors: Kazuhiko Kiuchi, Masayuki Kato, Masahiko Kagitani
  • Patent number: 6133359
    Abstract: A non-stick coating composition comprising fluorocarbon resins and from 5 to 25% by weight of refractory fibers. The composition preferably additionally includes a liquid medium in which the fibers are dispersed and the fluorocarbon is dispersed. The composition is then applied, the liquid medium driven off and the fluorocarbon resin cured.
    Type: Grant
    Filed: January 7, 1993
    Date of Patent: October 17, 2000
    Assignee: Whitford Plastics Limited
    Inventors: Thomas James Bate, Hugh Campbell Wilson