US4197385A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Furan-phenolic resins for collapsible foundry molds
Assignee: Unilever Bestfoods North America
•
Filing: 1978-08-11
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Granted: 1980-04-08
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Expires: 1998-08-11
Abstract
Abstract A resin for coating sand and a resin-coated sand produced therefrom wherein the resin is prepared by incorporating furan into a phenolic novolak resin. In the preferred practice, the resin is produced by reaction of furfuryl alcohol with a phenolic compound at an acid pH to give a furfuryl-phenolic intermediate in a first step, and then, in a second step, reacting the furfuryl-phenolic intermediate with a lower aliphatic aldehyde to produce the resin. The resin-coated sands of the present invention provide unexpectedly improved shakeout and collapsibility characteristics in the shell process.
Inventors
- 👤 Robert Laitar
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 06:40
CPC Classifications
B; B22; B22C; B22C1/00; B22C1/16; B22C1/20; B22C1/22; B22C1/2233; B22C1/224; C; C08; C08L; C08L61/00; C08L61/34
Claims Analysis
Total Claims: 42
Claim 1
Independent Claim
87 words
A novolak resin prepared by: (a) reacting of furfuryl alcohol with a phenol at an acid pH, with the mole ratio of furfuryl alcohol to the phenol being within the range of 0.04 to 0.9, to produce a furfuryl-phenolic intermediate, and (b) reacting of said intermediate with a C 1 to C 3 aliphatic aldehyde at an acid pH, with the molar ratio of aldehyde to the total of the phenol and furfuryl alcohol being within the range of 0.5 to 0.85 and (c) separating the resin.
Claim 2
Dependent Claim
87 words
A novolak resin prepared by: (a) reacting of furfuryl alcohol with a phenol at an acid pH, with the mole ratio of furfuryl alcohol to the phenol being within the range of 0.04 to 0.9, to produce a furfuryl-phenolic intermediate, and (b) reacting of said intermediate with a C 1 to C 3 aliphatic aldehyde at an acid pH, with the molar ratio of aldehyde to the total of the phenol and furfuryl alcohol being within the range of 0.5 to 0.85 and (c) separating the resin.
Claim 3
Dependent Claim
17 words
A resin as defined in claim 1 wherein the phenol is phenol and the aldehyde is formaldehyde.
Claim 4
Dependent Claim
30 words
A resin as defined in claim 1 wherein the furfuryl alcohol is reacted with the phenol at a temperature within the range of about 40° C. to about 100° C.
Claim 5
Dependent Claim
23 words
A resin as defined in claim 1 wherein the intermediate is reacted with the aldehyde at a temperature of at least 60° C.
Claim 6
Dependent Claim
27 words
A resin as defined in claim 1 wherein the molar ratio of furfuryl alcohol to the phenol is within the range of about 0.05 to about 0.30.
Claim 7
Dependent Claim
25 words
A resin as defined in claim 1 wherein the reaction of the intermediate with the aldehyde is carried out at an acid pH below 6.
Claim 8
Dependent Claim
44 words
A resin as defined in claim 1 wherein the reaction of the phenol and furfuryl alcohol and the reaction of the intermediate with the aldehyde are carried out in the presence of an acid catalyst to maintain the pH of the reaction below 6.0.
Claim 9
Dependent Claim
30 words
A resin as defined in claim 7 wherein the acid catalyst is selected from the group consisting of sulfuric acid, hydrochloric acid, sulfamic acid, oxalic acid and phenol sulfonic acid.
Claim 10
Independent Claim
93 words
A method for the preparation of a furanmodified novolak resin comprising: (a) reacting of furfuryl alcohol with a phenol at an acid pH; with the mole ratio of furfuryl alcohol to the phenol being within the range of 0.04 to 0.9, to produce a furfuryl-phenolic intermediate, and (b) reacting of said intermediate with a C 1 to C 3 aliphatic aldehyde at an acid pH, with the molar ratio of aldehyde to the total of the phenol and furfuryl alcohol being within the range of 0.5 to 0.85 and (c) separating the resin.
Claim 11
Independent Claim
93 words
A method for the preparation of a furanmodified novolak resin comprising: (a) reacting of furfuryl alcohol with a phenol at an acid pH; with the mole ratio of furfuryl alcohol to the phenol being within the range of 0.04 to 0.9, to produce a furfuryl-phenolic intermediate, and (b) reacting of said intermediate with a C 1 to C 3 aliphatic aldehyde at an acid pH, with the molar ratio of aldehyde to the total of the phenol and furfuryl alcohol being within the range of 0.5 to 0.85 and (c) separating the resin.
Claim 12
Dependent Claim
17 words
A method as defined in claim 9 wherein the phenol is phenol and the aldehyde is formaldehyde.
Claim 13
Dependent Claim
30 words
A method as defined in claim 9 wherein the furfuryl alcohol is reacted with the phenol at a temperature within the range of about 40° C. to about 100° C.
Claim 14
Dependent Claim
23 words
A method as defined in claim 9 wherein the intermediate is reacted with the aldehyde at a temperature of at least 60° C.
Claim 15
Dependent Claim
27 words
A method as defined in claim 9 wherein the molar ratio of furfuryl alcohol to the phenol is within the range of about 0.05 to about 0.30.
Claim 16
Dependent Claim
25 words
A method as defined in claim 9 wherein the reaction of the intermediate with the aldehyde is carried out at an acid pH below 6.
Claim 17
Dependent Claim
44 words
A method as defined in claim 9 wherein the reaction of the phenol and furfuryl alcohol and the reaction of the intermediate with the aldehyde are carried out in the presence of an acid catalyst to maintain the pH of the reaction below 6.0.
Claim 18
Dependent Claim
30 words
A method as defined in claim 9 wherein the acid catalyst is selected from the group consisting of sulfuric acid, hydrochloric acid, sulfamic acid, oxalic acid and phenol sulfonic acid.
Claim 19
Dependent Claim
130 words
A novolak resin prepared by: (a) reacting a furan compound selected from the group consisting of furfuryl alcohol and furfural with a phenol in the presence of a basic or acid catalyst to promote a condensation reaction of the furan compound with the phenol, with the mole ratio of the furan compound to the phenol being within the range of 0.04 to 0.9, to produce a furan-phenolic intermediate, (b) reacting said intermediate with a C 1 to C 3 aliphatic aldehyde in the presence of a basic or acid catalyst to promote a condensation reaction between the aldehyde and the intermediate, with the mole ratio of the aldehyde to the total of the phenol and furan compound being within the range of 0.5 to 0.85, and (c) separating the resin.
Claim 20
Dependent Claim
130 words
A novolak resin prepared by: (a) reacting a furan compound selected from the group consisting of furfuryl alcohol and furfural with a phenol in the presence of a basic or acid catalyst to promote a condensation reaction of the furan compound with the phenol, with the mole ratio of the furan compound to the phenol being within the range of 0.04 to 0.9, to produce a furan-phenolic intermediate, (b) reacting said intermediate with a C 1 to C 3 aliphatic aldehyde in the presence of a basic or acid catalyst to promote a condensation reaction between the aldehyde and the intermediate, with the mole ratio of the aldehyde to the total of the phenol and furan compound being within the range of 0.5 to 0.85, and (c) separating the resin.
Claim 21
Dependent Claim
18 words
A resin as defined in claim 17 wherein the catalyst of (a) and (b) is an acid catalyst.
Claim 22
Dependent Claim
14 words
A resin as defined in claim 18 wherein the furan compound is furfuryl alcohol.
Claim 23
Dependent Claim
13 words
A resin as defined in claim 17 wherein the furan compound is furfural.
Claim 24
Dependent Claim
18 words
A resin as defined in claim 20 wherein the catalyst of (a) and (b) is a basic catalyst.
Claim 25
Dependent Claim
167 words
A resin prepared by: (a) providing a furan-containing resin selected from the group consisting of: (1) a furan resin prepared by reaction of furfuryl alcohol with a C 1 to C 3 aliphatic aldehyde in the presence of an acid catalyst, and (2) a furan modified resin prepared by reaction of a phenol and a C 1 to C 3 aliphatic aldehyde to produce a resole resin and then reacting the resole resin with furfuryl alcohol; and (b) blending the furan-containing resin with a novolak resin prepared by reaction of a phenol with a C 1 to C 3 aliphatic aldehyde, with the ratio of the total of the aldehyde contained in the furan-containing resin and the novolak resin to the phenol of the novolak resin and the furfuryl alcohol of the furan-containing resin being within the range of 0.5 to 0.85 and the ratio of furfuryl alcohol of the furan-containing resin to the phenol of the novolak resin is within the range of 0.04 to 0.9.
Claim 26
Dependent Claim
167 words
A resin prepared by: (a) providing a furan-containing resin selected from the group consisting of: (1) a furan resin prepared by reaction of furfuryl alcohol with a C 1 to C 3 aliphatic aldehyde in the presence of an acid catalyst, and (2) a furan modified resin prepared by reaction of a phenol and a C 1 to C 3 aliphatic aldehyde to produce a resole resin and then reacting the resole resin with furfuryl alcohol; and (b) blending the furan-containing resin with a novolak resin prepared by reaction of a phenol with a C 1 to C 3 aliphatic aldehyde, with the ratio of the total of the aldehyde contained in the furan-containing resin and the novolak resin to the phenol of the novolak resin and the furfuryl alcohol of the furan-containing resin being within the range of 0.5 to 0.85 and the ratio of furfuryl alcohol of the furan-containing resin to the phenol of the novolak resin is within the range of 0.04 to 0.9.
Claim 27
Dependent Claim
17 words
A resin as defined in claim 22 wherein the aldehyde is formaldehyde and the phenol is phenol.
Claim 28
Dependent Claim
45 words
A resin as defined in claim 22 wherein the furan-containing resin is (2), and the phenol is reacted with the aldehyde in the presence of a basic catalyst and the furfuryl alcohol is reacted with the resole resin in the presence of an acid catalyst.
Claim 29
Dependent Claim
20 words
A resin as defined in claim 22 wherein the novolak resin is prepared in the presence of an acid catalyst.
Claim 30
Dependent Claim
13 words
A resin as defined in claim 22 wherein the furan-containing resin is (1).
Claim 31
Independent Claim
135 words
A method for the preparation of a novolak resin comprising: (a) reacting a furan compound selected from the group consisting of furfuryl alcohol and furfural with a phenol in the presence of a base or acid catalyst to promote a condensation reaction of the furan compound with the phenol, with the mole ratio of the furan compound to the phenol being within the range of 0.04 to 0.9, to produce a furan-phenolic intermediate, (b) reacting said intermediate with a C 1 to C 3 aliphatic aldehyde in the presence of a basic or acid catalyst to promote a condensation reaction between the aldehyde and the intermediate, with the mole ratio of the aldehyde to the total of the phenol and furan compound being within the range of 0.5 to 0.85, and (c) separating the resin.
Claim 32
Independent Claim
135 words
A method for the preparation of a novolak resin comprising: (a) reacting a furan compound selected from the group consisting of furfuryl alcohol and furfural with a phenol in the presence of a base or acid catalyst to promote a condensation reaction of the furan compound with the phenol, with the mole ratio of the furan compound to the phenol being within the range of 0.04 to 0.9, to produce a furan-phenolic intermediate, (b) reacting said intermediate with a C 1 to C 3 aliphatic aldehyde in the presence of a basic or acid catalyst to promote a condensation reaction between the aldehyde and the intermediate, with the mole ratio of the aldehyde to the total of the phenol and furan compound being within the range of 0.5 to 0.85, and (c) separating the resin.
Claim 33
Dependent Claim
18 words
A method as defined in claim 27 wherein the catalyst of (a) and (b) is an acid catalyst.
Claim 34
Dependent Claim
14 words
A method as defined in claim 28 wherein the furan compound is furfuryl alcohol.
Claim 35
Dependent Claim
13 words
A method as defined in claim 27 wherein the furan compound is furfural.
Claim 36
Dependent Claim
18 words
A method as defined in claim 30 wherein the catalyst of (a) and (b) is a basic catalyst.
Claim 37
Independent Claim
172 words
A method for the preparation of a resin comprising: (a) providing a furan-containing resin selected from the group consisting of: (1) a furan resin prepared by reaction of furfuryl alcohol with a C 1 to C 3 aliphatic aldehyde in the presence of an acid catalyst, and (2) a furan modified resin prepared by reaction of a phenol and a C 1 to C 3 aliphatic aldehyde to produce a resole resin and then reacting the resole resin with furfuryl alcohol; and (b) blending the furan-containing resin with a novolak resin prepared by reaction of a phenol with a C 1 to C 3 aliphatic aldehyde, with the ratio of the total of the aldehyde contained in the furan-containing resin and the novolak resin to the phenol of the novolak resin and the furfuryl alcohol of the furan-containing resin being within the range of 0.5 to 0.85 and the ratio of furfuryl alcohol of the furan-containing resin to the phenol of the novolak resin is within the range of 0.04 to 0.9.
Claim 38
Independent Claim
172 words
A method for the preparation of a resin comprising: (a) providing a furan-containing resin selected from the group consisting of: (1) a furan resin prepared by reaction of furfuryl alcohol with a C 1 to C 3 aliphatic aldehyde in the presence of an acid catalyst, and (2) a furan modified resin prepared by reaction of a phenol and a C 1 to C 3 aliphatic aldehyde to produce a resole resin and then reacting the resole resin with furfuryl alcohol; and (b) blending the furan-containing resin with a novolak resin prepared by reaction of a phenol with a C 1 to C 3 aliphatic aldehyde, with the ratio of the total of the aldehyde contained in the furan-containing resin and the novolak resin to the phenol of the novolak resin and the furfuryl alcohol of the furan-containing resin being within the range of 0.5 to 0.85 and the ratio of furfuryl alcohol of the furan-containing resin to the phenol of the novolak resin is within the range of 0.04 to 0.9.
Claim 39
Dependent Claim
17 words
A method as defined in claim 32 wherein the aldehyde is formaldehyde and the phenol is phenol.
Claim 40
Dependent Claim
45 words
A method as defined in claim 32 wherein the furan-containing resin is (2), and the phenol is reacted with the aldehyde in the presence of a basic catalyst and the furfuryl alcohol is reacted with the resole resin in the presence of an acid catalyst.
Claim 41
Dependent Claim
20 words
A method as defined in claim 32 wherein the novolak resin is prepared in the presence of an acid catalyst.
Claim 42
Dependent Claim
13 words
A method as defined in claim 32 wherein the furan-containing resin is (1).
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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) | 1983-04-08 | 1983-10-08 | 1984-04-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-04-08 | 1987-10-08 | 1988-04-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-04-08 | 1991-10-08 | 1992-04-08 | $7700.00 | Window Closed / Lapsed |