US4474904A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Foundry moulds and cores
Assignee: Hexion UK Ltd
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Filing: 1982-10-14
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Granted: 1984-10-02
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Expires: 2002-10-14
Abstract
Abstract A foundry moulding composition comprising (a) a granular refractory material, (b) from 0.25 to 2.5% based on the weight of the refractory material of an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50 to 75% and said resin having a weight average molecular weight (M wr ) of from 700 to 2000, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.5:1 to 1.2:1; (c) from 0.05 to 3% based on the weight of said aqueous solution, of at least one silane, and (d) from 20 to 110% based on the weight of said aqueous solution of at least one ester active to catalyze curing of said resin.
Inventors
- 👤 Peter H. R. B. Lemon
- 👤 Jeffrey D. Railton
- 👤 Derek W. Baker
- 👤 Vincent J. Coppock
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 16:43
CPC Classifications
B; B22; B22C; B22C1/00; B22C1/16; B22C1/20; B22C1/22; B22C1/2233; B22C1/2246; B22C1/2253; C; C08; C08G; C08G8/00; C08G8/04; C08G8/08; C08G8/10; C08G8/28; C08L; C08L61/00; C08L61/04; C08L61/06; C08L61/14
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
126 words
A foundry moulding composition comprising (a) a granular refractory material, (b) from 0.25 to 2.5% based on the weight of the refractory material of an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50 to 75% and said resin having a weight average molecular weight (M w ) of from 700 to 2000, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.5:1 to 1.2:1; (c) from 0.05 to 3% based on the weight of said aqueous solution, of at least one silane, and (d) from 20 to 110% based on the weight of said aqueous solution of at least one ester active to catalyze curing of said resin.
Claim 2
Dependent Claim
126 words
A foundry moulding composition comprising (a) a granular refractory material, (b) from 0.25 to 2.5% based on the weight of the refractory material of an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50 to 75% and said resin having a weight average molecular weight (M w ) of from 700 to 2000, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.5:1 to 1.2:1; (c) from 0.05 to 3% based on the weight of said aqueous solution, of at least one silane, and (d) from 20 to 110% based on the weight of said aqueous solution of at least one ester active to catalyze curing of said resin.
Claim 3
Dependent Claim
29 words
The composition of claim 1 wherein the refractory material is selected from the group comprising silica sand, quartz, chromite sand, zircon, olivine sand or beach sands containing shell fragments.
Claim 4
Dependent Claim
20 words
The composition of claim 2 wherein the refractory material is chromite sand, olivine sand or beach sands containing shell fragments.
Claim 5
Dependent Claim
17 words
The composition of claim 1 wherein the M w of said resin is from 800 to 1700.
Claim 6
Dependent Claim
14 words
The composition of claim 4 wherein said M w is from 950 to 1700.
Claim 7
Dependent Claim
18 words
The composition of claim 1 or 4 wherein the potassium hydroxide:phenol molar ratio is from 0.6:1 to 1.2:1.
Claim 8
Dependent Claim
10 words
The composition of claim 1 wherein said silane is γ-aminopropyltriethoxysilane.
Claim 9
Dependent Claim
22 words
The composition of claim 1 wherein from 25% to 40% by weight of said aqueous solution of said ester catalyst is present.
Claim 10
Dependent Claim
32 words
The composition of claim 8 wherein said ester is a low molecular weight lactone or an ester of a C 1-10 alkyl mono- or polyhydric alcohol with a C 1-10 carboxylic acid.
Claim 11
Dependent Claim
18 words
The composition of claim 9 wherein said lactone is selected from the group comprising γ-butyrolactone, propiolactone and ξ-caprolactone.
Claim 12
Dependent Claim
12 words
The composition of claim 9 wherein said carboxylic acid is acetic acid.
Claim 13
Dependent Claim
11 words
The composition of claim 11 wherein said ester is glycerol triacetate.
Claim 14
Dependent Claim
154 words
A process for the production of foundry moulds or cores which comprises, mixing granular refractory material with a binder, wherein said binder comprises (a) from 0.25% to 2.5% based on the weight of the refractory material of an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50% to 75% and said resin having a weight average molecular weight (M w ) of from 700 to 2000, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.5:1 to 1.2:1, (b) from 0.05% to 3% based on the weight of said aqueous solution of at least one silane, and (c) from 20% to 110% based on the weight of said aqueous solution of at least one ester active to catalyze curing of said resin, discharging the mixture into a corebox or pattern mold, and allowing the resin to cure.
Claim 15
Dependent Claim
154 words
A process for the production of foundry moulds or cores which comprises, mixing granular refractory material with a binder, wherein said binder comprises (a) from 0.25% to 2.5% based on the weight of the refractory material of an aqueous solution of a potassium alkali phenol-formaldehyde resin, said aqueous solution having a solids content of from 50% to 75% and said resin having a weight average molecular weight (M w ) of from 700 to 2000, a formaldehyde:phenol molar ratio of from 1.2:1 to 2.6:1 and a potassium hydroxide:phenol molar ratio of from 0.5:1 to 1.2:1, (b) from 0.05% to 3% based on the weight of said aqueous solution of at least one silane, and (c) from 20% to 110% based on the weight of said aqueous solution of at least one ester active to catalyze curing of said resin, discharging the mixture into a corebox or pattern mold, and allowing the resin to cure.
Claim 16
Dependent Claim
29 words
The process of claim 13 wherein the refractory material is selected from the group comprising silica sand, quartz, chromite sand, zircon, olivine sand or beach sands containing shell fragments.
Claim 17
Dependent Claim
20 words
The process of claim 14 wherein the refractory material is chromite sand, olivine sand or beach sands containing shell fragments.
Claim 18
Dependent Claim
17 words
The process of claim 14 wherein the M w of said resin is from 800 to 1700.
Claim 19
Dependent Claim
16 words
The process of claim 16 wherein the potassium hydroxide:phenol molar ratio is from 0.6:1 to 1.2:1.
Claim 20
Dependent Claim
22 words
The process of claim 13 wherein from 25% to 40% by weight of said aqueous solution of said ester catalyst is utilized.
Claim 21
Dependent Claim
22 words
The process of claim 17 wherein from 25% to 40% by weight of said aqueous solution of said ester catalyst is present.
Claim 22
Dependent Claim
32 words
The process of claim 19 wherein said ester is a low molecular weight lactone or an ester of a C 1-10 alkyl mono- or polyhydric alcohol with a C 1-10 carboxylic acid.
Claim 23
Dependent Claim
12 words
The process of claim 20 wherein said carboxylic acid is acetic acid.
Claim 24
Dependent Claim
11 words
The process of claim 21 wherein said ester is glycerol triacetate.
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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) | 1987-10-02 | 1988-04-02 | 1988-10-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-10-02 | 1992-04-02 | 1992-10-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-10-02 | 1996-04-02 | 1996-10-02 | $7700.00 | Window Closed / Lapsed |