US4283319A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for preparing foundry cores or molds and binder materials used therefor
Assignee: Resonac Corp
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Filing: 1979-11-07
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Granted: 1981-08-11
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Expires: 1999-11-07
Abstract
Abstract A novel process for preparing foundry cores or molds and binder materials used therefor are provided. The binder materials comprise (a) an alcohol-soluble phenolic resin, (b) a polyvalent metal hydroxide and/or oxide, (c) water, (d) an organic solvent, and (e) an alkali metal hydroxide. They are admixed with refractory particles, such as sand, and cured with carbon dioxide to form shaped foundry cores or molds. The process and materials of the invention bring about such advantages that curing may be performed with safe carbon dioxide, that shaped foundry cores or molds may be taken out from pattern immediately after curing, and that the products have a superior collapsibility after pouring a molten metal.
Inventors
- 👤 Susumu Konii
- 👤 Shigeo Sase
- 👤 Masatoshi Yoshida
- 👤 Shoei Kuroda
- 👤 Takeshi Sumi
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 22:11
CPC Classifications
C; C08; C08G; C08G8/00; C08G8/04; B; B22; B22C; B22C1/00; B22C1/16; B22C1/20; B22C1/22; B22C1/2233; B22C1/2246; B22C1/2253; C08K; C08K3/00; C08K3/18; C08K3/20; C08K3/22
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
148 words
A foundry binder material to be cured with carbon dioxide which comprises (a) an alcohol-soluble phenolic resin selected from the group consisting of resoles, novolacs, N-methylene-resoles, dimethylene ether-type resoles, formal-type resoles and mixtures thereof, (b) 10 to 300 parts by weight of a hydroxide and/or oxide of a polyvalent metal selected from the group consisting of an alkaline earth metal, aluminum, zinc, iron, nickel, titanium, silicon, tin, and a mixture thereof, (c) 100-500 parts by weight of water, (d) 1 to 100 parts by weight of an organic solvent selected from the group consisting of an alcohol, an aromatic hydrocarbon, a ketone, an acetic ester, a phthalic ester, an ether, a cellosolve, dimethylformamide, dimethyl sulfoxide and a mixture thereof, and (e) 0.1 to 50 parts by weight of an alkali metal hydroxide, said parts by weight being based on 100 parts by weight of said alcohol-soluble phenolic resin.
Claim 2
Dependent Claim
148 words
A foundry binder material to be cured with carbon dioxide which comprises (a) an alcohol-soluble phenolic resin selected from the group consisting of resoles, novolacs, N-methylene-resoles, dimethylene ether-type resoles, formal-type resoles and mixtures thereof, (b) 10 to 300 parts by weight of a hydroxide and/or oxide of a polyvalent metal selected from the group consisting of an alkaline earth metal, aluminum, zinc, iron, nickel, titanium, silicon, tin, and a mixture thereof, (c) 100-500 parts by weight of water, (d) 1 to 100 parts by weight of an organic solvent selected from the group consisting of an alcohol, an aromatic hydrocarbon, a ketone, an acetic ester, a phthalic ester, an ether, a cellosolve, dimethylformamide, dimethyl sulfoxide and a mixture thereof, and (e) 0.1 to 50 parts by weight of an alkali metal hydroxide, said parts by weight being based on 100 parts by weight of said alcohol-soluble phenolic resin.
Claim 3
Dependent Claim
21 words
The material according to claim 1, wherein the alcohol-soluble phenolic resin has a number-average molecular weight of not less than 400.
Claim 4
Dependent Claim
21 words
The material according to claim 2, wherein the alcohol-soluble phenolic resin has a number-average molecular weight of not less than 500.
Claim 5
Dependent Claim
21 words
The material according to claim 3, wherein the alcohol-soluble phenolic resin has a number-average molecular weight of not less than 800.
Claim 6
Dependent Claim
16 words
The material according to claim 1, wherein the alcohol-soluble phenolic resin is a novolak-type phenolic resin.
Claim 7
Dependent Claim
17 words
The material according to claim 1, wherein the alcohol-soluble phenolic resin is an alcohol-soluble resol-type phenolic resin.
Claim 8
Dependent Claim
17 words
The material according to claim 6, wherein the alcohol-soluble resol-type phenolic resin is a resol-type phenol/formaldehyde resin.
Claim 9
Dependent Claim
24 words
The material according to claim 1, wherein the alcohol-soluble phenolic resin is a mixture of a novolak-type phenolic resin and a resol-type phenolic resin.
Claim 10
Dependent Claim
20 words
The material according to claim 1, wherein the polyvalent metal hydroxide and/or oxide are alkaline earth metal hydroxide and/or oxide.
Claim 11
Dependent Claim
19 words
The material according to claim 9, wherein the alkaline earth metal hydroxide and/or oxide are calcium hydroxide and/or oxide.
Claim 12
Dependent Claim
13 words
The material according to claim 1, wherein the organic solvent is an alcohol.
Claim 13
Dependent Claim
13 words
The material according to claim 11, wherein the alcohol is a lower alcohol.
Claim 14
Dependent Claim
12 words
The material according to claim 12, wherein the lower alcohol is methanol.
Claim 15
Dependent Claim
13 words
The material according to claim 11, wherein the alcohol is a polyhydric alcohol.
Claim 16
Dependent Claim
15 words
The material according to claim 14, wherein the polyhydric alcohol is glycerin or ethylene glycol.
Claim 17
Dependent Claim
20 words
The material according to claim 11, wherein the alcohol is a mixture of a lower alcohol and a polyhydric alcohol.
Claim 18
Dependent Claim
14 words
The material according to claim 1, wherein the alkali metal hydroxide is sodium hydroxide.
Claim 19
Dependent Claim
159 words
A foundry binder composition which comprises: (a) an alcohol-soluble phenolic resin selected from the group consisting of a resole, a novolac, an N-methylene-resole, a dimethylene ether-type resole, a formal-type resole and a mixture thereof; (b) 10 to 300 parts by weight of a hydroxide and/or an oxide of a polyvalent metal selected from the group consisting of an alkaline earth metal, aluminum, zinc, iron, nickel, titanium, silicon, tin, and a mixture thereof; (c) 100-500 parts by weight of water; (d) 1 to 100 parts by weight of an organic solvent selected from the group consisting of an alcohol, an aromatic hydrocarbon, a ketone, an acetic ester, a phthalic ester, an ether, a cellosolve, dimethylformamide, dimethyl sulfoxide and a mixture thereof; (e) 0.1 to 50 parts by weight of an alkali metal hydroxide and (f) a curing amount of carbon dioxide as curing agent, said parts by weight being based on 100 parts by weight of said alcohol-soluble phenolic resin.
Claim 20
Dependent Claim
159 words
A foundry binder composition which comprises: (a) an alcohol-soluble phenolic resin selected from the group consisting of a resole, a novolac, an N-methylene-resole, a dimethylene ether-type resole, a formal-type resole and a mixture thereof; (b) 10 to 300 parts by weight of a hydroxide and/or an oxide of a polyvalent metal selected from the group consisting of an alkaline earth metal, aluminum, zinc, iron, nickel, titanium, silicon, tin, and a mixture thereof; (c) 100-500 parts by weight of water; (d) 1 to 100 parts by weight of an organic solvent selected from the group consisting of an alcohol, an aromatic hydrocarbon, a ketone, an acetic ester, a phthalic ester, an ether, a cellosolve, dimethylformamide, dimethyl sulfoxide and a mixture thereof; (e) 0.1 to 50 parts by weight of an alkali metal hydroxide and (f) a curing amount of carbon dioxide as curing agent, said parts by weight being based on 100 parts by weight of said alcohol-soluble phenolic resin.
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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) | 1984-08-10 | 1985-02-09 | 1985-08-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-08-10 | 1989-02-09 | 1989-08-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-08-10 | 1993-02-09 | 1993-08-11 | $7700.00 | Window Closed / Lapsed |