Cold-setting compositions for foundry sand cores and molds

Claim 2

A cold-setting foundry composition useful for foundry cores and molds comprising: (a) a particulate refractory material; (b) between about 0.5 and about 6 parts by weight per 100 parts of particulate refractory material of a resin binder; (c) between about 10 parts and about 70 parts by weight per 100 parts of resin binder of an acidic curing catalyst; and (d) between about 2 parts and about 30 parts by weight per 100 parts of resin binder of an accelerator selected from the group: dihydroxybenzenes, monoalkyl, monoaryl, and aralkyl derivatives of dihydroxybenzenes, trihydroxybenzenes, and mixtures thereof.

Claim 3

The composition of claim 1 wherein the accelerator is selected from the group: resorcinol, catechol, hydroquinone, and phloroglucinol.

Claim 4

The composition of claim 1 wherein the accelerator is dissolved in a polar solvent.

Claim 5

The composition of claim 3 wherein the polar solvent is an alcohol.

Claim 6

The composition of claim 4 wherein the alcohol is furfuryl alcohol.

Claim 7

A "no-bake" process for making a shaped article, such as a foundry core or mold, which comprises: (a) mixing a particulate refractory material, an acidic catalyst, a resin binder, and between about 2 parts and about 30 parts by weight per 100 parts of resin binder of an accelerator selected from the group: dihydroxybenzenes, monoalkyl, monoaryl, and aralkyl derivatives of dihydroxybenzenes, trihydroxybenzenes, and mixtures thereof; (b) forming the mixture of refratory material, catalyst, binder, and accelerator into the desired shape; and (c) allowing the shaped mixture to cure at ambient conditions to produce such shaped article.

Claim 8

A "no-bake" process for making a shaped article, such as a foundry core or mold, which comprises: (a) mixing a particulate refractory material, an acidic catalyst, a resin binder, and between about 2 parts and about 30 parts by weight per 100 parts of resin binder of an accelerator selected from the group: dihydroxybenzenes, monoalkyl, monoaryl, and aralkyl derivatives of dihydroxybenzenes, trihydroxybenzenes, and mixtures thereof; (b) forming the mixture of refratory material, catalyst, binder, and accelerator into the desired shape; and (c) allowing the shaped mixture to cure at ambient conditions to produce such shaped article.

Claim 9

The process of claim 6 wherein the accelerator is selected fromt he group: resorcinol, catechol, hydroquinone, and phloroglucinol.

Claim 10

The process of claim 6 wherein the accelerator is dissolved in a polar solvent.

Claim 11

the process of claim 8 wherein the polar solvent is an alochol.

Claim 12

The process of claim 9 wherein the alcohol is furfuryl alcohol.

Claim 13

The shaped article formed by the process of claim 6.

Claim 14

The shaped article formed by the process of claim 7.

Claim 15

The shaped article formed by the process of claim 9.

Claim 16

The shaped article formed by the process of claim 10.