Process of forming a shell mold from a water, furfuryl alcohol, sand and catalyst composition

Claim 1

A PROCESS FOR FORMING A SHELL MOLD FROM A WATER, FURFURYL ALCOHOL, SAND AND ACID-REACTING CATALYST COMPOSITION, SAID PROCESS COMPRISING THE STEPS OF MIXING SAID WATER, SAND AND ACID-REACTING CATALYST UNTIL A FIRST SUBSTANTIALLY HOMOGENOUS MIXTURE IS FORMED, ADDING BETWEEN ABOUT 2.5 AND 10% OF FURFURYL ALCOHOL BASED ON THE WEIGHT OF SAID SAND UNTIL A SECOND SUBSTANTIALLY HOMOGENEOUS MIXTURE IS FORMED HAVING GOOD GREEN STRENGTH, AND APPLYING SAID SECOND HOMOGENEOUS MIXTURE WITHIN APPROXIMATELY 16 HOURS AFTER FORMATION THEREOF TO A PATTERN HAVA TEMPERATURE OF BETWEEN ABOUT 400* -600* F., WHEREBY SAID FURFURYL ALCOHOL IS RESINIFIED IN A SINGLE STAGE, SAID ACID REACTING CATALYST BEING SELECTED FROM THE GROUP CONSISTIG OF FERRIC CHLORIDE, ZINC CHLORIDE, FERROUS CHLORIDE AND OXALIC ACID AND PRESENT IN A SUFFICIENT QUANTITY TO NEUTRALIZE THE ALKALINE VALUES OF SAID SAND AND TRIGGER POLYMERIZATION OF SAID FURFURYL ALCOHOL AT SAID TEMPERATURE OF BETWEEN ABOUT 400* -600* F., SAID WATER BEING PRESENT IN A QUANTITY SUFFICIENT TO FACILITATE MIXING AND ENABLE ACID FORMATION TO TAKE PLACE.