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.

Abstract: A binder composition of a phenolic novolac resin and a (lower) alkoxylated triazine-formaldehyde resin curing agent is disclosed. The triazine resins have sufficient carbon atoms in the alkoxy groups so as to provide a curing agent having a water solubility of less than 15%. The binder cures at high temperatures so as to provide improved flow and prolonged workability to the composition. The compositions are useful in refractory applications having a need for high temperature curing agents such as for maintenance and repair within refractory vessels by gunning/spraying, manufacture of electrodes by the Soderberg method, and for use in blast furnace tap holes.

Abstract: This invention relates to a polyurethane no-bake foundry binder comprising (1) phenolic resin component which comprises (a) a phenolic resin, (b) hydrofluoric acid, and (c) a silane, and (2) an organic polyisocyanate component, and (3) a liquid tertiary amine catalyst component. The binders are used to prepare foundry mixes by mixing the binder with a foundry aggregate. Foundry shapes are prepared with the mixes by the no-bake process and are used to cast metal parts.

Abstract: Two or more sand additive particles are made to adhere to each other, using a binder. The finished product consists of free-flowing particles that are composed of the additive particles bound together by the binder. These bound additive particles may then be applied to sand, such as foundry sands, where, otherwise, multiple additions of additive might need to be made. The pH of the single additive particles can be controlled and separation of the additives due to different specific gravities can be avoided. Various mixtures of different additives are disclosed. Methods of controlling particle size of additive particles, tendency to generate dust, degrade tensile strength or control thermal expansion of foundry cores or molds by using bound additive particles are also disclosed.

Abstract: Binder compositions for a mold each comprising a specific alkaline phenol-aldehyde resin are disclosed. Methods for producing a mold using any of the binder compositions are also disclosed.

Abstract: There is provided a composition that is the product of mixing and reaction a resole, an alcoholate of an amino triazine, and aldehyde. This composition is useful as a thermosetting resin. This composition is useful as a curative for novolac resins. There is also provided a process for making this composition. In particular there is a process disclosed for making this composition in aqueous solution. Furthermore, curable novolac compositions, and processes for making these compositions, are disclosed and claimed.

Abstract: This invention relates to benzylic ether phenolic resole resins prepared in a sealed reaction vessel and their uses. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Abstract: A coated sand composition for light-alloy casting includes refractory particles blended with phenol resin, bromide and adsorbent which adsorbs decomposition product gas from the bromide.

Abstract: Broadly, the present invention relates to furan no-bake foundry binders where bisphenol A tar (BPAT) is used to replace a portion of the furfuryl alcohol and any conventional filler optionally included in for binder formulation. Reduction in the amount of furfuryl alcohol in the foundry binder formulation may lead to a reduction in the cost and an improvement in early strength of these formulations. Accordingly, in a furan no-bake foundry binder of a resin derived from a major proportion of furfuryl alcohol and optionally fillers, the improvement which comprises at least a fraction of said furfuryl alcohol being bisphenol A tar. Bisphenol A tar also can replace at least a fraction of any filler included in the binder formulation.

Abstract: An improved feedstock material for D-RIM type PIM processes to manufacture parts. The feedstock includes metal or powders or a mixture thereof which is coated with a surfactant to improve rheology and keep the powder from inhibiting a catalytic reaction which occurs during the process. A condensation thermosetting resin is mixed with a latent catalyst and added to the mixture. A modifier can also be added to the mixture, as can a latent catalyst which is a metal salt such as copper triflate. The constituents when mixed together form a uniform feedstock which is injected into a heated mold. The mixtures cures in the mold and a partial debinding occurs. When the part is removed from the mold, it is sintered. Addition of the copper triflate adds significantly to the green strength of the part, and allows parts to be made at least as quickly as parts made from other feedstock materials. Hydrating the copper triflate greatly increases the shelf life of the feedstock.

Abstract: A binder solution of a phenolic novolak resin in solvent, preferably furfuryl alcohol containing at least one chemical agent such as amines containing one to five, preferably two to four, nitrogen atoms, glycerine or mixtures thereof. Preferably, the binder solution contains about 0.2 to about 1.5 weight percent water. The binder solution is for binding refractory objects, preferably those containing doloma (calcined dolomite) aggregate. Methods of mixing these ingredients and using the mixture are also disclosed. Bricks made from the doloma aggregate mixed with the binder solution show good ambient temperature green strength and enhanced modulus of rupture after curing and coking.

Abstract: The object of the present invention is to provide a spray-on (gunning) refractory composition having high anti-stripping property, adhesive strength and corrosion resistant property suitable even for high temperature operation in steelmaking furnace. To refractory materials, resol type phenolic resin powder, being in semi-melting state at 80.degree. C. to 500.degree. C. and having weight average molecular weight of 1,000 to 15,000 and residual monomer of not more than 1,000 ppm, or phenol-formaldehyde resin powder, being in heat melting, self-hardening state at 100.degree. C. to 500.degree. C., having weight average molecular weight of 1,000 to 15,000 and residual monomer of not more than 1,000 ppm, and containing reactive methylol group by 6 to 9 weight %, said phenol-formaldehyde resin powder being added by 2 to 10 weight %, and pitch with high softening point of 100.degree. C. to 500.degree. C. being added by 2 to 10 weight %.

Abstract: A binder solution of a phenolic novolak resin in solvent, preferably furfuryl alcohol containing at least one chemical agent such as amines containing one to five, preferably two to four, nitrogen atoms, glycerine or mixtures thereof. Preferably, the binder solution contains about 0.2 to about 1.5 weight percent water. The binder solution is for binding refractory objects, preferably those containing doloma (calcined dolomite) aggregate. Methods of mixing these ingredients and using the mixture are also disclosed. Bricks made from the doloma aggregate mixed with the binder solution show good ambient temperature green strength and enhanced modulus of rupture after curing and coking.

Abstract: A liquid binding agent comprised of a phenolic resin, thinning agents and a curing agent, characterized in that the phenolic resin is produced by condensation catalyzed under alkaline conditions of a phenol and formaldehyde in a molar ratio of phenolic compound to formaldehyde in the range of 1:0.05 to 1.

Abstract: A binder composition of a phenolic novolac resin and a (lower) alkoxylated triazine-formaldehyde resin curing agent is disclosed. The triazine resins have sufficient carbon atoms in the alkoxy groups so as to provide a curing agent having a water solubility of less than 15%. The binder cures at high temperatures so as to provide improved flow and prolonged workability to the composition. The compositions are useful in refractory applications having a need for high temperature curing agents such as for maintenance and repair within refractory vessels by gunning/spraying, manufacture of electrodes by the Soderberg method, and for use in blast furnace tap holes.

Abstract: A binder resin composition, a curing agent composition, a caking additive composition, a kit, a casting mold composition and a process for manufacturing a casting mold are disclosed, wherein a metallic compound containing a metallic element belonging to Group IB to VIII of the Periodic Table is utilized. The compositions are useful for the production of a sand mold for casting, having an excellent strength, from reclaimed sand, in a self-hardening or gas hardening mold process. The casting mold according to the present invention, which is manufactured in the presence of a metallic compound containing a metallic element belonging to Group IB to VIII of the Perioidic Table has excellent strength.

Abstract: Two or more sand additive particles are made to adhere to each other, using a binder. The finished product consists of free-flowing particles that are composed of the additive particles bound together by the binder. These bound additive particles may then be applied to sand, such as foundry sands, where, otherwise, multiple additions of additive might need to be made. The pH of the single additive particles can be controlled and separation of the additives due to different specific gravities can be avoided. Various mixtures of different additives are disclosed. Methods of controlling particle size of additive particles, tendency to generate dust, degrade tensile strength or control thermal expansion of foundry cores or molds by using bound additive particles are also disclosed.

Abstract: Sand compositions containing a binder composition and a curing agent, in which the binder composition comprises (a) a binder comprising an acid-curable resin and (b) from 0.5 to 63.0% by weight, based on the binder composition, of at least one curing accelerator selected from compounds represented by formula (1): ##STR1## wherein X.sub.1, X.sub.2 each represent a hydrogen atom, a methyl group or an ethyl group;exhibit an increased curing rate to provide a casting mold having an increased initial strength.

Abstract: The invention relates to a casting core composition including refractory mullite grains and 1.0-2.2 wt % of a phenolic resin for binding the mullite grains. The mullite grains are substantially spherical in shape and have a special grain size distribution. That is, the mullite grains contain first to eighth fractions. These fractions respectively have first to eighth diameters which are respectively within ranges of larger than 420 .mu.m, 297-420 .mu.m 210-297 .mu.m, 149-210 .mu.m, 105-149 .mu.m, 74-105 .mu.m, 53-74 .mu.m, and smaller than 53 .mu.m.

Abstract: A foundry mold is produced from sand by blending, with one another, sand, a binder comprising a ester cured-phenolic resin, a curing agent comprising an organic ester compound and one or more additives containing therein a metal of the groups IB to VIII, and molding and curing the mixture into a foundry mold. The mixture is useful in a self-curing molding method and a vapour curing molding method, and the resulting mold is thereby provided with an unexpected improved mechanical strength. In particular the invention is advantageously effective with used or reclaimed refractory sand.

Abstract: Curable furan resins modified with phenolic resins for use as binders for cements and coating compositions having improved thermal stability, processes for their preparation and their use.Preparation of curable furan resins modified with phenolic resins based on condensation products of alkylidenepolyphenols of the novolak type with furfuryl alcohol or mixtures thereof with other reactive furan derivatives, furthermore curable solutions thereof in reactive organic solvents, processes for their preparation and their use as binders having improved thermal stability for preparing self-curing, chemically resistant and high-temperature-resistant cements and coating compositions.

Abstract: This invention relates to a process for reclaiming ester-cured phenolic resin bonded sand. The process comprises contacting attrition reclaimed sand with a compound which converts potassium compounds to a form having a melting point of least 550.degree. C., and then thermally treating the sand at a temperature below that which the resulting potassium compound fuses.

Abstract: This invention relates to a hot-box foundry mix. The hot-box foundry mix comprises (a) an aggregate (b) a thermosetting resin; (c) a latent acid curing catalyst; and (d) an effective benchlife extending amount of a compound selected from the group consisting of an alkaline earth metal carbonate, an alkaline earth metal oxide, and mixtures thereof. The hot-box foundry mixes are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

Abstract: The invention relates to an ester cured no-bake foundry binder system preferably comprising as separate components (a) an aqueous basic solution of a phenolic resole resin; and (b) a hardener comprising (i) a polyphenol resin, and (ii) a liquid ester. Alternatively, the polyphenol resin can be used as a separate component. The foundry binder systems produce foundry shapes with improved tensile strengths when compared to foundry shapes which are prepared from foundry binder systems which do not contain a polyphenol resin.

Abstract: The object of the present invention is to develop an innovative mud material which has the properties of a resin-type mud material for improving the working environment, which mud material is capable of increasing the depth of an iron tap hole and of improving the adhesion to mud material deposited in a furnace at high heat, such adhesion being a drawback of the conventional art.This invention provides a mud material used for an iron tap hole in a blast furnace, wherein 8 to 20 wt % of a solution of a novolak-type phenolic resin having a specific number-average molecular weight and serving as a binder is added to and blended with a refractory aggregate used as a conventional mud material.

Abstract: The invention relates to an ester cured no-bake foundry binder system preferably comprising as separate components (a) an aqueous basic solution of a phenolic resole resin; (b) a hardener comprising (i) an epoxy resin, and (ii) a liquid ester.

Abstract: This invention relates to a hardener for producing phenolic resins from phenolic resoles which comprises a partial phosphate ester. The hardener is produced by reacting condensed phosphoric acids with polyols at controlled temperatures with vigorous agitation under vacuum until constant acidity is achieved. The hardeners cure the phenolic resoles relatively slowly and therefore enable better control to be achieved when preparing moulded products.

Abstract: The subject invention relates to foundry mixes comprised of (a) an aqueous basic solution of a phenolic resole resin; (b) a major amount of reclaimed sand which has first been treated with an aqueous non halogenated surfactant solution, and (c) a liquid ester co-reactant.The invention also relates to foundry shapes made with the subject foundry mixes which have improved tensile strengths and scratch hardness when compared to foundry shapes which are prepared from foundry binder systems which do not utilize foundry aggregates which have been mixed with an aqueous surfactant solution.

Abstract: A phenolic resole resin for use as a foundry binder which has been internally modified to reduce its hot strength and thereby enhance its shakeout property is disclosed. The resin is the reaction product of a phenolic compound; a dialdehyde; and formaldehyde. A process of preparing such resin is also disclosed, comprising first reacting the phenolic compound and the dialdehyde, and subsequently reacting the product with the formaldehyde. The resin may be, in a preferred embodiment, an ester-curable alkaline phenolic resin. Also disclosed are a raw batch formulation including the resin of the invention, and foundry articles prepared therefrom.

Abstract: 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.

Abstract: This invention relates to a thixotropic laminating resin composition comprising an acid hardenable phenol-aldehyde resin, a highly dispersed hydrophobic amorphous silica and a viscosity modifier wherein the composition has a specified viscosity. Composites laminated with the above composition have improved dimensional stability and are resistant to combustion or smoke emission.

Abstract: A binder composition for producing articles of bonded particulate material such as foundry molds or core comprises an alkaline aqueous solution of a resol phenol-aldehyde resin, an oxyanion which can form a stable complex with the resin, and an ethylene glycol monoalkyl ether. The binder composition has an alkali to phenol molar ratio of from 1.5:1 to 2.5:1 and the amount of alkali present in the solution is sufficient to substantially prevent stable complex formation between the resin ad 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.

Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.

Abstract: The hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition at a pH of at least 4.5: a compound which provides an acetate, adipate, 4-aminobenzenesulfonate, 1,2,4-benzenetricarboxylate, formate, glycolate, lactate, nitrate, benzenesulfonate, naphthalenesulfonate, methanesulfonate, phenolsulfonate, succinate, sulfamate, or toluenesulfonate anion to the composition; or an acetylacetone, 2-nitrophenol, 4-nitrophenol, salicylaldehyde compound; or a mixture of said compounds.

Abstract: A binder composition for producing articles of bonded particulate material such as foundry molds or cores comprises an alkaline aqueous solution of a resol phenol-aldehyde resin, an oxyanion which can form a stable complex with the resin, and a phenyl ethylene glycol ether. The binder composition has an alkali to phenol molar ratio of from 1.5:1 to 2.5:1 and the amount of alkali present in the solution is sufficient to substantially prevent stable complex formation between the resin and the oxyanion. Bonded articles are produced by passing carbon dioxide gas through articles formed from a mixture of particulate material and the binder composition so as to produce stable complex formation and curing of the resin.

Abstract: The present invention provides methods for treating reclaimed sand obtained from dismantled foundry molds and cores which contain a cured binder derived from an ester cured alkaline phenolic resin. Treatment of the reclaimed sand with a silane solution, particularly an aqueous solution, enhances the tensile strengths of foundry molds and cores produced therefrom beyond those obtained with untreated reclaimed sand. Methods for producing foundry cores and molds which incorporate such a treatment process are also provided by this invention as are raw batch formulations.

Abstract: The present invention provides a binder solution having a low solids level which provides improved tensile properties when used with reclaimed sand. This binder solution comprises an alkaline phenolic resin which is cured at ambient temperature with an ester-functional curing agent. Also provided by this invention are raw batch formulations comprising sand, a binder solution having a low solids level, and a curing agent. These raw batch formulations include embodiments wherein the low solids levels are obtained by the separate addition of a solvent. The methods for producing foundry molds and cores of this invention included those procedures wherein dilution water is used to reduce the solids contents of conventional, relatively high solids content binder solutions.

Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.

Abstract: The hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition at a pH of at least 4.5: a compound which provides an acetate, adipate, 4-aminobenzeneslfonate, 1,2,4-benzenetricarboxylate, formate, glycolate, lactate, nitrate, benzenesulfonate, naphthalenesulfonate, methanesulfonate, phenolsulfonate, succinate, sulfamate, or toluenesulfonate anion to the composition; or an acetylacetone, 2-nitrophenol, 4-nitrophenol, salicylaldehyde compound; or a mixture of said compounds.

Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.

Abstract: There is disclosed methods and compositions for retarding the room temperature hardening of phenolic resole resins when such resins are mixed with lightburned magnesium oxide with or without an ester functional hardening agent. Compounds which act as retarders include azelaic acid, salicylamide, sulfanilic acid, glyoxal, salicylic acid, N-methylaniline, and 2,6-diethylaniline.

Abstract: 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.

Abstract: The present invention provides methods for treating reclaimed sand obtained from dismantled foundry molds and cores which contain a cured binder derived from an ester cured alkaline phenolic resin. Treatment of the reclaimed sand with a silane solution, particularly an aqueous solution, enhances the tensile strengths of foundry molds and cores produced therefrom beyond those obtained with untreated reclaimed sand. Methods for producing foundry cores and molds which incorporate such a treatment process are also provided by this invention as are raw batch formulations.

Abstract: 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.

Abstract: The hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition at a pH of at least 4.5: a compound which provides an acetate, adipate, 1,2,4-benzenetricarboxylate, formate, glycolate, lactate, nitrate, benzenesulfonate, naphthalenesulfonate, methanesulfonate, phenolsulfonate, succinate, sulfamate, or toluenesulfonate anion to the composition; or a mixture of said compounds.

Abstract: There are disclosed methods and compositions for accelerating the hardening of phenolic resole resins having a pH of about 4.5 to 9.5 with lightburned magnesium oxide or magnesium hydroxide, with or without the addition of an ester functional hardening agent. Acceleration of hardening is achieved by incorporating into said compositions an effective quantity of a material which: increases the solubility of magnesium in the hardenable mixture; by certain amines; or by certain chelating agents. Accelerator compounds include those which provide chloride, sulfamate, nitrate, formate, and phosphite anions as well as selected tertiary amines.

Abstract: There is disclosed methods and compositions for retarding the room temperature hardening of phenolic resole resins when such resins are mixed with lightburned magnesium oxide with or without an ester functional hardening agent. Compounds which act as retarders include azelaic acid, salicylamide, sulfanilic acid, N-methylaniline, and 2,6-diethylaniline.

Abstract: Retarding the hardening of a composition containing a phenolic resin solution and a magnesia aggregate is effected by mixing into such composition a compound which provides an aspartate, fluoride, bifluoride, malate, tartrate, citrate, oxalate, phosphate or phosphonate anion to the composition or a tetraalkoxy silane, a partially hydrolyzed tetraalkoxy silane, 2-, or 4-chlorophenol, or 2'-, or 4'-hydroxyacetophenone.

Abstract: A foundry sand mold is produced by molding a granular refractory material with the use of (1) a binder comprising a silane coupling agent, a water-soluble phenolic resin and a silane compound selected from an alkyl silicate having 1 to 8 carbon atoms in the alkyl group, its lower condensate, a silicone oil and a modified silicone oil and (2) a hardening agent comprising an organic ester.

Abstract: 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.