US4426467A — Foundry molding compositions and process

Claim 1

Independent Claim 53 words

A foundry moulding composition comprising: (a) a granular refractory material; (b) about 0.8 to 5.0% of an alkaline phenolic resin based on the weight of the refractory material; (c) about 25 to 110% of a lactone based on the weight of the penolic resin, said composition is capable of setting at ambient temperatures.

Claim 2

Dependent Claim 53 words

A foundry moulding composition comprising: (a) a granular refractory material; (b) about 0.8 to 5.0% of an alkaline phenolic resin based on the weight of the refractory material; (c) about 25 to 110% of a lactone based on the weight of the penolic resin, said composition is capable of setting at ambient temperatures.

Claim 3

Dependent Claim 16 words

The composition of claim 1 wherein the refractory material is a sand having an alkaline reaction.

Claim 4

Dependent Claim 17 words

The composition of claim 2 wherein the sand is olivine, chromite, or beach sands containing shell fragments.

Claim 5

Dependent Claim 34 words

The composition of claim 1 wherein the phenolic resin is the reaction product of phenol, m-cresol, 3,5-xylen-1-ol, resorcinol or mixtures thereof and an aldehyde selected from the group consisting of formaldehyde, acetaldehyde or furfuraldehyde.

Claim 6

Dependent Claim 15 words

The composition of claim 4 wherein the phenolic resin is that of phenol and formaldehyde.

Claim 7

Dependent Claim 18 words

The composition of claim 5 wherein the ratio of phenol to formaldehyde is from about 1:1.0 to 1:3.0.

Claim 8

Dependent Claim 18 words

The composition of claim 6 wherein the ratio of phenol to formaldehyde is from about 1:1.5 to 1:2.6.

Claim 9

Dependent Claim 30 words

The composition of claim 1 wherein the phenolic resin has a solids content of between 60 to 95% and a viscosity of about 0.5 to 100 poises at 25° C.

Claim 10

Dependent Claim 32 words

A composition of claim 8 wherein the said solids content of the phenolic is from about 80 to 95% and the viscosity is between about 5 to 15 poises at 25° C.

Claim 11

Dependent Claim 25 words

A composition of claim 1 which includes from about 0.1 to 3% of a silane having adhesion promoter properties between said resin and said refractory.

Claim 12

Dependent Claim 74 words

A process for the production of foundry moulds and cores which comprises mixing: (a) refractory granules with; (b) about 0.8 to 5.0% of an alkaline phenolic binder based on the weight of the refractory material; (c) about 25 to 110% of a lactone based on the weight of the said binder; and (d) rapidly discharging the mixture so formed into a corebox or pattern mold, said mixture is capable of setting at ambient temperatures.

Claim 13

Dependent Claim 74 words

A process for the production of foundry moulds and cores which comprises mixing: (a) refractory granules with; (b) about 0.8 to 5.0% of an alkaline phenolic binder based on the weight of the refractory material; (c) about 25 to 110% of a lactone based on the weight of the said binder; and (d) rapidly discharging the mixture so formed into a corebox or pattern mold, said mixture is capable of setting at ambient temperatures.

Claim 14

Dependent Claim 36 words

A process of claim 11 wherein the mixture has a pH above 7.6 and a minor quantity of a silane adhesion promotor is added to the mixture prior to discharge into a corebox or pattern mold.

Claim 15

Dependent Claim 16 words

A process of claim 11 wherein the refractory granules are a sand having an alkaline reaction.

Claim 16

Dependent Claim 39 words

The process of claim 11 wherein the lactone is mixed first with the said refractory granules, and then the said phenolic binder is mixed with said granules, prior to discharge of the mixture into a corebox or pattern mold.

Claim 17

Dependent Claim 36 words

The process of claim 11, 12, 13 or 14 comprising adding a small amount of a concentrated solution of an alkali metal hydroxide to said mixture before discharging the mixture into a corebox or pattern mold.

Claim 18

Dependent Claim 112 words

A process for the production of foundry molds and cores which comprises the following steps: mixing together particles of a sand that has an alkaline reaction and gamma-butyrolactone, then mixing therewith an alkali-catalyzed phenol-formaldehyde resin binder in an amount from about 1% to about 2% of the binder by weight based on the sand, the amount of said lactone being in the range from about 40% to about 60% by weight based on the said phenolic binder, then mixing therewith a small amount of a concentrated aqueous solution of an alkali metal hydroxide, before discharging the mixture, and then rapidly thereafter discharging the mixture so formed into a corebox or pattern mold.

Claim 19

Dependent Claim 112 words

A process for the production of foundry molds and cores which comprises the following steps: mixing together particles of a sand that has an alkaline reaction and gamma-butyrolactone, then mixing therewith an alkali-catalyzed phenol-formaldehyde resin binder in an amount from about 1% to about 2% of the binder by weight based on the sand, the amount of said lactone being in the range from about 40% to about 60% by weight based on the said phenolic binder, then mixing therewith a small amount of a concentrated aqueous solution of an alkali metal hydroxide, before discharging the mixture, and then rapidly thereafter discharging the mixture so formed into a corebox or pattern mold.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-01-16	1987-07-18	1988-01-17	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-01-16	1991-07-18	1992-01-17	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-01-16	1995-07-18	1996-01-17	$7700.00	Window Closed / Lapsed

Foundry molding compositions and process

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