Thermosetting composition comprising coal acids, phenol aldehyde resin, plasticizer and polyamine and method of preparing shell molds therefrom

Claim 1

METHOD FOR FABRICATION OF SHELL MOLDINGS WHICH COMPRISES INTIMATELY BLENDING SAND HAVING AN AFS FINENESS NUMBER THAT IS IN THE NUMERICAL RANGE BETWEEN ABOUT 25 AND 180 WITH BETWEEN ABOUT 3 AND 10 PERCENT BY WEIGHT, BASED ON THE WEIGHT OF THE RESULTING BLEND, OF A THERMOSETTING, RESIN-PROVIDING COMPOSITION: SAID THERMOSETTING RESIN-PROVIDING COMPOSITION BEING COMPRISED OF A MIXTURE OF (A) BETWEEN ABOUT 4 AND 50 PERCENT BY WEIGHT OF COAL ACIDS THAT ARE THE WATER-SOLUBLE, MIXED AROMATIC POLYCARBOXYLIC ACID PRODUCTS OF THE CLASS TAINED BY OXIDATION OF COAL, WHICH ACIDS HAVE AN AVERAGE MOLECULAR WEIGHT OF FROM 200 TO 300, AN APPARENT AVERAGE EQUIVALENT WEIGHT OF FROM 70 TO 90, AND CONTAIN AN AVERAGE OF FROM 2.5 TO 5 CARBOXYLIC GROUPS PER AROMATIC NUCLEUS IN THEIR MOLECULE; (B) BETWEEN ABOUT 20 TO 90 PERCENT BY WEIGHT OF A RESINOUS NOVALK CONDENSATION PRODUCT OF A PHENOL AND AN ALDEHYDE THAT CONTAINS FROM 3 TO 10 PHENOLIC UNITS IN ITS MOLECULE; (C) BETWEEN ABOUT 2 TO 30 PERCENT BY WEIGHT OF A HIGH MELTING PLASTICIZER INGREDIENT WHICH MELTS AT A TEMPERATURE BETWEEN ABOUT 150 AND 500*F. AND WHICH IS ADAPTED TO PLASTICIZE SAID COAL ACIDS WHEN STROKED ON A HOT PLATE AT 300*F. IN A COMPOSITION WITH SAID COAL ACIDS CONSISTING OF ABOUT FOUR PARTS BY WEIGHT OF SAID COAL ACIDS, ONE PART BY WEIGHT OF SAID HIGH MELTING PLASTICIZER INGREDIENT AND ONE-EIGHT PART BY WEIGHT OF SAID HEXAMETHYLENETETRAMINE; AND (D) BETWEEN 4 AND 30 PER CENT BY WEIGHT OF A POLYAMINES CONSISTING AGENT SELECTED FROM THE GROUP OF POLYAMINES CONSISTING OF POPERAZINE, SUBSTITUTED POPERAZINES, MELAMINE, POLYAMINES OF THE FORMULAE: H2N-R-NH2 AND