Phenolic resin-polyisocyanate binder systems containing dialkyl phthalate solvents

Claim 2

A BINDER COMPOSITION COMPRISING IN ADMIXTURE A RESIN COMPONENT, A HARDENER COMPONENT, AND A CURING COMPONENT, SAID RESIN COMPONENT COMPRISING A SOLUTION IN AN ORGANIC SOLVENT COMPRISING AT LEAST A LIQUID DIALKYL PHTHALATE OF A NON-AQUEOUS PHENOLIC RESIN WHICH COMPRISES A CONDENSATION PRODUCT OF A PHENOL HAVING THE GENERAL FORMULA:

Claim 3

The binder composition of claim 1, wherein the aldehyde is formaldehyde.

Claim 4

The binder composition of claim 1, wherein the aldehyde is formaldehyde, and A and B are hydrogen, and C is a hydrocarbon radical.

Claim 5

The binder composition of claim 1, wherein the aldehyde is formaldehyde and A, B, and C are hydrogen.

Claim 6

The binder composition of claim 1, wherein the phenolic resin is a novolak resin.

Claim 7

The composition of claim 1 wherein the dialkyl phthalate has the following formula:

Claim 8

The composition of claim 6 wherein R1 and R2 each are alkyl radicals of 3 to 6 carbon atoms and the total number of carbon atoms in R1 and R2 is between 6 and 12.

Claim 9

The composition of claim 7 wherein the dialkyl phthalate is selected from the group consisting of dibutyl phthalate, dioctyl phthalate and dicapryl phthalate.

Claim 10

The binder composition of claim 1 wherein the phenolic resin is a novolak resin.

Claim 11

The binder composition of claim 1, wherein the phenolic resin has the general formula:

Claim 12

The binder composition of claim 10 wherein R is hydrogen.

Claim 13

The binder composition of claim 1, wherein the polyisocyanate is an aromatic polyisocyanate.

Claim 14

The binder composition of claim 12 wherein the aromatic polyisocyanate is diphenylmethane diisocyanate.

Claim 15

The binder composition of claim 10, wherein the polyisocyanate is an aromatic polyisocyanate.

Claim 16

The binder composition of claim 10 wherein the dialkyl phthalate has the structural formula:

Claim 17

The binder composition of claim 15 wherein R1 and R2 each are alkyl radicals of 3 to 6 carbon atoms and the total number of carbon atoms in R1 and R2 is between 6 and 12.

Claim 18

The binder composition of claim 15 wherein R1 and R2 each are alkyl radicals selected from the group consisting of butyl, octyl, and capryl.

Claim 19

The binder composition of claim 15 wherein the percent by weight of dialkyl phthalate in the solvent is between about 10 and about 100.

Claim 20

The binder composition of claim 1, wherein the solvent includes at least one non-polar solvent.

Claim 21

The binder Composition of claim 1, wherein the curing agent is selected from the group consisting of tertiary amines and bases the latter having a pkb value in the range of about 7 to about 11.

Claim 22

A foundry mix containing sand as the major constituent and a binding amount of up to 10% based on the weight of sand of the binder of claim 1.

Claim 23

A foundry mix containing sand as the major constituent and a binding amount of up to 10% based on the weight of sand of the binder of claim 10.

Claim 24

The process of preparing shaped foundry products which comprises: a. forming a foundry mix by uniformly distributing on a foundry aggregate containing sand as the major constituent a binding amount of up to 10% based on the weight of the aggregate of a binder composition obtained by combining the phenolic resin component and hardener component of claim 1, said polyisocyanate being employed in a concentration of 10 to 500% by weight of the phenolic resin; b. shaping the foundry mix in a mold; and, c. curing the shaped foundry mix with a catalyst selected from the group consisting of gaseous tertiary amines and liquid bases.

Claim 25

The process of claim 23, wherein the resin component of the binder is the phenolic resin of claim 10.

Claim 26

The process of claim 24, wherein the polyisocyanate is an aromatic polyisocyanate.

Claim 27

The process of claim 23 wherein the foundry mix is prepared by admixing the foundry aggregate with the phenolic resin component and thereafter admixing the resulting mixture with the hardener component.