Patent US2409885A successfully refreshed from Google Patents.
Patent US4495316A successfully refreshed from Google Patents.
US4495316A
Expired / Lapsed
US
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Acid-curable fluoride-containing no-bake foundry resins
Assignee: Hexion Inc
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Filing: 1976-09-23
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Granted: 1985-01-22
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Expires: 1996-09-23
Abstract
Abstract A suspension or solution containing an acid-curable fluoride-containing resin which is useful in a foundry process is disclosed. The fluoride-containing resin is curable at room temperatures and above by the addition of a strong acid catalyst. The resin is preferably a phenolic resole resin or a furan-type resin. The fluoride-containing resins, when used in a foundry process are preferably admixed with a foundry sand and a strong acid catalyst. The coated sand is then shaped into the form of a foundry core and is allowed to cure at room temperature or above to a foundry core having excellent tensile strength.
Inventors
- 👤 David R. Armbruster
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 09:04
CPC Classifications
B; B22; B22C; B22C1/00; B22C1/16; B22C1/20; B22C1/22; B22C1/2233; C; C08; C08K; C08K3/00; C08K3/16
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
108 words
An acid-curable resin binder solution consisting essentially of: (a) a resinous material selected from the group consisting of phenolic resole resins, furan resins, resorcinol resins, phenolic resorcinol resins, ethylene urea-terminated resins characterized by the formula: ##STR2## wherein X is an organic structure having a molecular weight of from about 100 to about 5000 and n is greater than one and mixtures thereof; (b) a compound that generates fluoride during acid-curing of the prepolymer; and (c) a hydrophilic solvent for said resinous material, said solvent being present in an amount sufficient to provide a viscosity in the range of from about 10 to about 1000 cps at 25° C.
Claim 2
Dependent Claim
108 words
An acid-curable resin binder solution consisting essentially of: (a) a resinous material selected from the group consisting of phenolic resole resins, furan resins, resorcinol resins, phenolic resorcinol resins, ethylene urea-terminated resins characterized by the formula: ##STR2## wherein X is an organic structure having a molecular weight of from about 100 to about 5000 and n is greater than one and mixtures thereof; (b) a compound that generates fluoride during acid-curing of the prepolymer; and (c) a hydrophilic solvent for said resinous material, said solvent being present in an amount sufficient to provide a viscosity in the range of from about 10 to about 1000 cps at 25° C.
Claim 3
Dependent Claim
27 words
An acid-curable resin binder in accordance with claim 1, wherein said resinous material has a molecular weight in the range of from about 100 to about 1000.
Claim 4
Dependent Claim
27 words
An acid-curable resin binder in accordance with claim 2, wherein said resinous material has a molecular weight in the range of from about 100 to about 500.
Claim 5
Dependent Claim
17 words
An acid-curable resin binder in accordance with claim 1, wherein said resinous material is a furan resin.
Claim 6
Dependent Claim
18 words
An acid-curable resin binder in accordance with claim 1, wherein said resinous material is a phenolic resole resin.
Claim 7
Dependent Claim
54 words
An acid-curable resin binder in accordance with claim 5, wherein said phenolic resole resin is the reaction product of an aldehyde selected from the group consisting of formaldehyde, paraformaldehyde, acetaldehyde, and furfural and a phenolic compound selected from the group consisting of phenol, ortho-cresol, meta-cresol, para-cresol, bisphenol-A, tert-butyl phenol, catechol, resorcinol and mixtures thereof.
Claim 8
Dependent Claim
28 words
An acid-curable resin binder in accordance with claim 6, wherein the mole ratio of aldehyde to phenolic compound is in the range of about 1:1 to about 2:1.
Claim 9
Dependent Claim
30 words
An acid-curable resin binder solution in accordance with claim 1, wherein the quantity of fluoride-containing compound utilized is from about 0.02% to about 5%, based on weight of resin binder.
Claim 10
Dependent Claim
30 words
An acid-curable resin binder solution in accordance with claim 1, wherein said fluoride-containing compound is selected from the group consisting of ammonium fluoride, ammonium bifluoride, ammonium fluoborate, and mixtures thereof.
Claim 11
Dependent Claim
37 words
An acid-curable resin binder solution in accordance with claim 1, wherein the solvent is present in an amount sufficient to provide a viscosity in the range of from about 10 to about 500 cps at 25° C.
Claim 12
Dependent Claim
33 words
An acid-curable resin binder solution in accordance with claim 1, wherein said hydrophilic solvent is selected from the group consisting of water, lower aliphatic alcohols, lower aliphatic ketones, furfuryl alcohol and mixtures thereof.
Claim 13
Independent Claim
162 words
A method for making shaped articles such as foundry cores comprising the steps of: (a) forming a mixture of a particulate refractory material and an acid catalyst; (b) adding to said mixture an acid-curable resin binder solution consisting essentially of a resin binder selected from the group consisting of phenolic resole resins, furan resins, resorcinol resins, phenolic resorcinol resins, ethylene urea-terminated resins characterized by the formula: ##STR3## wherein X is an organic structure having a molecular weight of from about 100 to about 5000 an n is greater than one, and mixtures thereof; a compound that generates fluoride ion during acid curing of the binder; and a hydrophilic solvent for said resin binder; said solvent being present in an amount sufficient to provide a viscosity in the range of from about 10 to about 1000 cps at 25° C.; (c) forming the mixture into the desired shape; and allowing said shaped mixture to cure at ambient conditions to produce said shaped article.
Claim 14
Independent Claim
162 words
A method for making shaped articles such as foundry cores comprising the steps of: (a) forming a mixture of a particulate refractory material and an acid catalyst; (b) adding to said mixture an acid-curable resin binder solution consisting essentially of a resin binder selected from the group consisting of phenolic resole resins, furan resins, resorcinol resins, phenolic resorcinol resins, ethylene urea-terminated resins characterized by the formula: ##STR3## wherein X is an organic structure having a molecular weight of from about 100 to about 5000 an n is greater than one, and mixtures thereof; a compound that generates fluoride ion during acid curing of the binder; and a hydrophilic solvent for said resin binder; said solvent being present in an amount sufficient to provide a viscosity in the range of from about 10 to about 1000 cps at 25° C.; (c) forming the mixture into the desired shape; and allowing said shaped mixture to cure at ambient conditions to produce said shaped article.
Claim 15
Dependent Claim
15 words
A method in accordance with claim 12, wherein said resin binder is a furan resin.
Claim 16
Dependent Claim
16 words
A method in accordance with claim 12, wherein said resin binder is a phenolic resole resin.
Claim 17
Dependent Claim
50 words
A method in accordance with claim 14, wherein said phenolic resole resin binder is the reaction product of an aldehyde selected from the group consisting of formaldehyde, paraformaldehyde, acetaldehyde and furfural and the phenolic compound selected from the group of phenol, ortho-cresol, meta-cresol, bis-phenol-A, tert-butyl-phenol, catechol, resorcinol and mixtures thereof.
Claim 18
Dependent Claim
26 words
A method in accordance with claim 15, wherein the mole ratio of aldehyde to phenolic compound is in the range of about 1:1 to about 2:1.
Claim 19
Dependent Claim
25 words
A method in accordance with claim 12, wherein said resin binder has a molecular weight in the range of from about 100 to about 1000.
Claim 20
Dependent Claim
25 words
A method in accordance with claim 12, wherein said resin binder has a molecular weight in the range of from about 100 to about 500.
Claim 21
Dependent Claim
27 words
A method in accordance with claim 12, wherein the quantity of fluoride-containing compound utilized is from about 0.02% to about 5%, based on weight of resin binder.
Claim 22
Dependent Claim
27 words
A method in accordance with claim 12, wherein said fluoride-containing compound is selected from the group consisting of ammonium fluoride, ammonium bifluoride, ammonium fluoborate, and mixtures thereof.
Claim 23
Dependent Claim
34 words
A method in accordance with claim 12, wherein the solvent is present in an amount sufficient to provide a viscosity in the range of from about 10 to about 500 cps at 25° C.
Claim 24
Dependent Claim
30 words
A method in accordance with claim 12, wherein said hydrophilic solvent is selected from the group consisting of water, lower aliphatic alcohols, lower aliphatic ketones, furfuryl alcohol and mixtures thereof.
Claim 25
Dependent Claim
32 words
A method in accordance with claim 12, wherein said acid catalyst is selected from the group consisting of p-toluene sulfonic acid, phenol sulfonic acid, benzene sulfonic acid, phosphoric acid and mixtures thereof.
Claim 26
Dependent Claim
5 words
The product of claim 13.
Claim 27
Dependent Claim
5 words
The product of claim 14.
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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) | 1988-01-22 | 1988-07-23 | 1989-01-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-01-22 | 1992-07-23 | 1993-01-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-01-22 | 1996-07-23 | 1997-01-22 | $7700.00 | Window Closed / Lapsed |