Resin-coated sand compositions

Claim 1

In the process for preparation of a composition useful as a foundry core or mold consisting essentially of sand and a phenolic resin wherein a mixture of the phenolic resin consisting of solid particles and sand at an elevated temperature sufficient to fluidize said solid resin are mulled to coat the sand with said resin, the improvement wherein the solid phenolic resin comprises a solid novolac phenolic resin and a lubricant-containing solid resole phenolic resin produced by the reaction comprising condensation of a phenol and a formaldehyde source followed by dehydration of the reaction mixture wherein the lubricant is added prior to or during said reaction to produce the solid resole phenolic resin, the novolac resin constituting about 1 to about 40 parts by weight per 100 parts by weight of the phenolic resin, and the lubricant-containing resole phenolic resin constituting the balance of the phenolic resin component, the proportion of the total phenolic resin being about 2 to about 5 parts by weight per 100 parts by weight of the sand and the proportion of lubricant in the resole resin component being about 0.5 to about 10 parts by weight per 100 parts by weight of the resole resin component.