US4079031A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Improved foundry process and binder resin composition therefor
Assignee: Delta Oil Products Corp
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Filing: 1976-07-14
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Granted: 1978-03-14
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Expires: 1996-07-14
Abstract
Abstract An improved binder resin is disclosed for use in a foundry process, comprising a major proportion of a resole phenolic resin and a minor proportion of a polyether polyol and a mutual solvent therefor, wherein the polyol has an average molecular weight between about 200 and 5000 and a hydroxy functionality of about 2 to 4. The improved binder is used in the foundry process by mixing it with a polyisocyanate and preferably an amine catalyst.
Inventors
- 👤 Kashinath S. Sardessai
- 👤 Jordan J. Kopac
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 01:08
CPC Classifications
C; C08; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/54; C08G18/542; B; B22; B22C; B22C1/00; B22C1/16; B22C1/20; B22C1/22; B22C1/2233; B22C1/2273; C08G18/4009; C08G18/4027; C08G8/00; C08G8/04; C08G8/08; C08G8/10; C08K; C08K3/00; C08K3/34; C08K3/36; C08L; C08L61/00; C08L61/04; C08L61/06; C08L71/00; C08L71/02; C08L75/00; C08L75/04
Claims Analysis
Total Claims: 16
Claim 1
Independent Claim
136 words
The process of preparing shaped foundry products which comprises: (a) forming a foundry mix by uniformly distributing a foundry aggregate containing sand as a major constituent in a binding amount of up to 10% based on the weight of the aggregate of a binder resin composition comprising a resole phenolic resin, a minor proportion of a polyether polyol, and a mutual solvent system therefor, said polyol having an average molecular weight between about 200 and 5000 and having an average hydroxyfunctionality between about 2 and 4; (b) mixing therewith a polyisocyanate in a concentration of 10 to 500% by weight of the phenolic resin; (c) shaping the foundry mix in a mold; and (d) permitting said binder resin composition to react with said polyisocyanate to form a thermoset copolymer and to bind the shaped foundry mix.
Claim 2
Dependent Claim
136 words
The process of preparing shaped foundry products which comprises: (a) forming a foundry mix by uniformly distributing a foundry aggregate containing sand as a major constituent in a binding amount of up to 10% based on the weight of the aggregate of a binder resin composition comprising a resole phenolic resin, a minor proportion of a polyether polyol, and a mutual solvent system therefor, said polyol having an average molecular weight between about 200 and 5000 and having an average hydroxyfunctionality between about 2 and 4; (b) mixing therewith a polyisocyanate in a concentration of 10 to 500% by weight of the phenolic resin; (c) shaping the foundry mix in a mold; and (d) permitting said binder resin composition to react with said polyisocyanate to form a thermoset copolymer and to bind the shaped foundry mix.
Claim 3
Dependent Claim
20 words
The process of claim 1, comprising the additional step of passing a gaseous tertiary amine through the shaped foundry mix.
Claim 4
Dependent Claim
16 words
The process of claim 1, wherein the foundry mix of (a) includes a tertiary amine catalyst.
Claim 5
Dependent Claim
22 words
The process of claim 3, wherein the tertiary amine catalyst is selected from the group consisting of 4-phenyl propyl pyridine and 4-picoline.
Claim 6
Dependent Claim
16 words
The process of claim 3, wherein an organo-metallic co-catalyst is added to the tertiary amine catalyst.
Claim 7
Dependent Claim
12 words
The process of claim 5, wherein the co-catalyst is an organo-tin compound.
Claim 8
Dependent Claim
12 words
The process of claim 5, wherein the co-catalyst is dibutyl tin dilaurate.
Claim 9
Dependent Claim
32 words
A process as described in claim 1, wherein the binder resin composition includes from about 10 to about 40% by weight of said polyol, based on the weight of said phenolic resin.
Claim 10
Dependent Claim
19 words
A process as described in claim 1, wherein said phenolic resin contains at least 5% by weight of water.
Claim 11
Dependent Claim
21 words
A process as described in claim 1, wherein said binder resin composition includes a minor proportion of a novolac phenolic resin.
Claim 12
Dependent Claim
31 words
A process as described in claim 10, wherein the binder resin composition includes from about 10 to about 40% by weight of said polyol, based on the weight of said phenolic.
Claim 13
Dependent Claim
20 words
A process as described in claim 10, wherein said resole phenolic resin contains at least 5% by weight of water.
Claim 14
Dependent Claim
22 words
The process of claim 3, wherein the tertiary amine catalyst is selected from a group consisting of 4-phenyl propyl pyridine and 4-picoline.
Claim 15
Dependent Claim
16 words
The process of claim 3, wherein an organometallic co-catalyst is added to the tertiary amine catalyst.
Claim 16
Dependent Claim
20 words
The process of claim 3 wherein the order of mixing is sand, binder resin composition, polyisocyanate, and tertiary amine catalyst.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-03-13 | 1981-09-12 | 1982-03-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-03-13 | 1985-09-12 | 1986-03-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-03-13 | 1989-09-12 | 1990-03-14 | $7700.00 | Window Closed / Lapsed |