US4939188A — Lithium-containing resole composition for making …

Claim 1

Independent Claim 59 words

A curable binder composition comprising (a) a phenol formaldehyde resole resin; (b) an ester-functional curing agent in an amount sufficient to effect the ambient temperature cure of the resole resin; and, (c) a lithium ion-generating alkalizing agent present in an amount sufficient to produce in the composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1.

Claim 2

Dependent Claim 59 words

A curable binder composition comprising (a) a phenol formaldehyde resole resin; (b) an ester-functional curing agent in an amount sufficient to effect the ambient temperature cure of the resole resin; and, (c) a lithium ion-generating alkalizing agent present in an amount sufficient to produce in the composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1.

Claim 3

Dependent Claim 34 words

A binder composition as in claim 1 wherein the resole resin is the reaction product of a phenolic material and formaldehyde and wherein the formaldehyde:phenol molar ratio is between about 1:1 and about 3:1.

Claim 4

Dependent Claim 59 words

A binder composition as in claim 1 wherein the binder composition further comprises a phenol formaldehyde novolac component having a formaldehyde:phenol mole ratio in the range of about 0.5:1 to about 0.9:1, wherein said novolac and said resole are present in the binder composition in a weight ratio of novolac to resole of from about 5:1 to about 0.35:1.

Claim 5

Dependent Claim 10 words

A binder composition as in claim 1 further comprising water.

Claim 6

Dependent Claim 39 words

A binder composition as in claim 1 further comprising an organic solvent for the resin selected from the group consisting of C 1 -C 7 aliphatic and aromatic alcohols, C 2 -C 4 glycols, glycol ethers, and mixtures thereof.

Claim 7

Dependent Claim 36 words

A binder composition as in claim 1 wherein the lithium ion-generating alkalizing agent is selected from the group consisting of lithium oxide, lithium hydroxide, lithium methoxide, lithium ethoxide, monolithium salt of ethylene glycol, and mixtures thereof.

Claim 8

Dependent Claim 80 words

A binder-aggregate material comprising (a) a phenol formaldehyde resole resin; (b) an ester-functional curing agent in an amount sufficient to effect the ambient temperature cure of the resole resin; (c) a lithium ion-generating alkalizing agent present in an amount sufficient to produce in the composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1; and (d) a particulate aggregate material, wherein the weight ratio of resole resin to aggregate material is from about 2:100 to about 1:7.

Claim 9

Dependent Claim 80 words

A binder-aggregate material comprising (a) a phenol formaldehyde resole resin; (b) an ester-functional curing agent in an amount sufficient to effect the ambient temperature cure of the resole resin; (c) a lithium ion-generating alkalizing agent present in an amount sufficient to produce in the composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1; and (d) a particulate aggregate material, wherein the weight ratio of resole resin to aggregate material is from about 2:100 to about 1:7.

Claim 10

Dependent Claim 13 words

The binder-aggregate material of claim 7 further comprising a phenol formaldehdye novolac resin.

Claim 11

Dependent Claim 53 words

The binder-aggregate material of claim 7 wherein the particulate aggregate material is selected from the group consisting of magnesia, alumina, zirconia, zircon sand, olivine sand, silicon carbide, silicon nitride, boron nitride, silica, bauxite, corundum, pumice, perlite, vermiculite, limestone, quartz, sand, gravel, crushed rock, broken brick, air cooled blast furnace slag, and mixtures thereof.

Claim 12

Dependent Claim 53 words

The binder-aggregate material of claim 8 wherein the particulate aggregate material is selected from the group consisting of magnesia, alumina, zirconia, zircon sand, olivine sand, silicon carbide, silicon nitride, boron nitride, silica, bauxite, corundum, pumice, perlite, vermiculite, limestone, quartz, sand, gravel, crushed rock, broken brick, air cooled blast furnace slag, and mixtures thereof.

Claim 13

Dependent Claim 56 words

A binder composition as in claim 1 wherein the ester-functional curing agent is selected from the group consisting of lactones, cyclic organic carbonates, carboxylic acid esters, aromatic formates, aromatic acetates and mixtures thereof, and is present in an amount up to about 40% by weight based on the weight of resole resin in the binder composition.

Claim 14

Dependent Claim 56 words

A binder-aggregate material as in claim 7 wherein the ester-functional curing agent is selected from the group consisting of lactones, cyclic organic carbonates, carboxylic acid esters, and mixtures thereof, and is present in an amount of from about 5% to about 25% by weight based on the weight of the resole resin in the binder composition.

Claim 15

Dependent Claim 56 words

A binder-aggregate material as in claim 8 wherein the ester-functional curing agent is selected from the group consisting of lactones, cyclic organic carbonates, carboxylic acid esters, and mixtures thereof, and is present in an amount of from about 5% to about 25% by weight based on the weight of the resole resin in the binder composition.

Claim 16

Dependent Claim 56 words

A binder-aggregate material as in claim 9 wherein the ester-functional curing agent is selected from the group consisting of lactones, cyclic organic carbonates, carboxylic acid esters, and mixtures thereof, and is present in an amount of from about 5% to about 25% by weight based on the weight of the resole resin in the binder composition.

Claim 17

Dependent Claim 56 words

A binder-aggregate material as in claim 10 wherein the ester-functional curing agent is selected from the group consisting of lactones, cyclic organic carbonates, carboxylic acid esters, and mixtures thereof, and is present in an amount of from about 5% to about 25% by weight based on the weight of the resole resin in the binder composition.

Claim 18

Dependent Claim 44 words

A binder-aggregate material as in claim 9 wherein the ester-functional curing agent is selected from the group consisting of diacetin, triacetin, butyrolactone, caprolactone, methyl formate, ethyl formate, ethylene carbonate, propylene carbonate, dimethyl esters of succinic acid, glutaric acid, and adipic acid and mixtures thereof.

Claim 19

Dependent Claim 48 words

A binder aggregate material as in claim 7 further comprising at least one additive selected from the group consisting of non-reactive solvents, silanes, clays, graphite, iron oxide, carbon pitch, silicon dioxide, aluminum powder, magnesium powder, silicon powder, calcium oxide, calcium hydroxide, magnesium oxide, magnesium hydroxide and mixtures thereof.

Claim 20

Dependent Claim 48 words

A binder aggregate material as in claim 9 further comprising at least one additive selected from the group consisting of non-reactive solvents, silanes, clays, graphite, iron oxide, carbon pitch, silicon dioxide, aluminum powder, magnesium powder, silicon powder, calcium oxide, calcium hydroxide, magnesium oxide, magnesium hydroxide and mixtures thereof.

Claim 21

Dependent Claim 16 words

A binder composition as in claim 1 wherein the lithium ion-generating alkalizing agent is lithium hydroxide.

Claim 22

Dependent Claim 24 words

A binder composition as in claim 3 further comprising a methylene generating material selected from the group consisting of formaldehyde, hexamethylene tetramine, and paraformaldehyde.

Claim 23

Dependent Claim 18 words

The curable binder composition of claim 1 wherein the phenol formaldehyde resole resin comprises phenol, cresol and formaldehyde.

Claim 24

Dependent Claim 18 words

The curable binder compositon of claim 1 wherein the phenol formaldehyde resole resin comprises phenol, xylenol and formaldehyde.

Claim 25

Dependent Claim 18 words

The curable binder composition of claim 3 wherein the phenol formaldehyde novolac component comprises phenol, cresol and formaldehyde.

Claim 26

Dependent Claim 18 words

The curable binder composition of claim 3 wherein the phenol formaldehyde novolac component comprises phenol, xylenol and formaldehyde.

Claim 27

Dependent Claim 161 words

A shaped article for use in making a refractory article comprising aggregate material bonded together by a cured binder composition, said binder composition in its uncured state comprising a phenol formaldehyde resole resin, an ester-functional curing agent, and a lithium ion-generating alkalizing agent selected from the group consisting of lithium oxide, lithium hydroxide, lithium methoxide, lithium ethoxide, monolithium salt of ethylene glycol, and mixtures thereof, wherein the lithium ion-generating alkalizing agent is present in an amount sufficient to produce in the binder composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1, and the ester-functional curing agent is present in an amount sufficient to cure at ambient temperature the resole resin and wherein the aggregate material is selected from the group consisting of magnesia, alumina, silica, zirconia, zircon sand, olivine sand, silicon carbide, silicon nitride, boron nitride, bauxite, corundum, pumice, perlite, vermiculite, limestone, quartz, sand, gravel, crushed rock, broken brick, air cooled blast furnace slag, and mixtures thereof.

Claim 28

Dependent Claim 161 words

A shaped article for use in making a refractory article comprising aggregate material bonded together by a cured binder composition, said binder composition in its uncured state comprising a phenol formaldehyde resole resin, an ester-functional curing agent, and a lithium ion-generating alkalizing agent selected from the group consisting of lithium oxide, lithium hydroxide, lithium methoxide, lithium ethoxide, monolithium salt of ethylene glycol, and mixtures thereof, wherein the lithium ion-generating alkalizing agent is present in an amount sufficient to produce in the binder composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1, and the ester-functional curing agent is present in an amount sufficient to cure at ambient temperature the resole resin and wherein the aggregate material is selected from the group consisting of magnesia, alumina, silica, zirconia, zircon sand, olivine sand, silicon carbide, silicon nitride, boron nitride, bauxite, corundum, pumice, perlite, vermiculite, limestone, quartz, sand, gravel, crushed rock, broken brick, air cooled blast furnace slag, and mixtures thereof.

Claim 29

Dependent Claim 46 words

The shaped article of claim 25 further comprising at least one additive selected from the group consisting of non-reactive solvents, silanes, clays, graphite, iron oxide, carbon pitch, silicon dioxide, aluminum powder, magnesium powder, silicon powder, calcium oxide, calcium hydroxide, magnesium oxide, magnesium hydroxide and mixtures thereof.

Claim 30

Dependent Claim 35 words

A shaped article as in claim 26 wherein the binder composition further comprises a phenol formaldehyde novolac resin, wherein the weight ratio of novolac resin to resole resin is from about 5:1 to about 0.35:1.

Claim 31

Dependent Claim 23 words

A shaped article as in claim 26 comprising a phenol formaldehyde resole resin, an ester-functional curing agent, lithium oxide alkalizing agent and alumina.

Claim 32

Dependent Claim 23 words

A shaped article as in claim 26 comprising a phenol formaldehyde resole resin, an ester-functional curing agent, lithium oxide alkalizing agent and magnesia.

Claim 33

Dependent Claim 23 words

A shaped article as in claim 27 comprising a phenol formaldehyde resole resin, an ester-functional curing agent, lithium oxide alkalizing agent and alumina.

Claim 34

Dependent Claim 23 words

A shaped article as in claim 27 comprising a phenol formaldehyde resole resin, an ester-functional curing agent, lithium oxide alkalizing agent and magnesia.

Claim 35

Dependent Claim 164 words

A shaped article comprising (a) a phenol formaldehyde resin binder composition comprising in its uncured state (i) a phenol formaldehyde novolac resin having a formaldehyde:phenol mole ratio in the range of about 0.5:1 to about 0.9:1, and (ii) a phenol formaldehyde resole resin having a formaldehyde:phenol mole ratio in the range of about 1:1 to about 3:1, wherein said novolac and said resole resins are present in a weight ratio of novolac to resole of between about 5:1 and about 0.35:1 and wherein the phenol is selected from the group consisting of phenol, cresol and xylenol; (b) an ester-functional curing agent; (c) lithium oxide alkalizing agent; and (d) an aggregate material selected from the group consisting of silica, alumina and magnesia present in an amount up to 97% by weight of the shaped article, and wherein the pH of the resin binder composition is sufficiently alkaline to cure the resin binder composition, at ambient temperature, and bind the aggregate material into a desired shape.

Claim 36

Dependent Claim 164 words

A shaped article comprising (a) a phenol formaldehyde resin binder composition comprising in its uncured state (i) a phenol formaldehyde novolac resin having a formaldehyde:phenol mole ratio in the range of about 0.5:1 to about 0.9:1, and (ii) a phenol formaldehyde resole resin having a formaldehyde:phenol mole ratio in the range of about 1:1 to about 3:1, wherein said novolac and said resole resins are present in a weight ratio of novolac to resole of between about 5:1 and about 0.35:1 and wherein the phenol is selected from the group consisting of phenol, cresol and xylenol; (b) an ester-functional curing agent; (c) lithium oxide alkalizing agent; and (d) an aggregate material selected from the group consisting of silica, alumina and magnesia present in an amount up to 97% by weight of the shaped article, and wherein the pH of the resin binder composition is sufficiently alkaline to cure the resin binder composition, at ambient temperature, and bind the aggregate material into a desired shape.

Claim 37

Dependent Claim 54 words

The shaped article of claim 32 further comprising at least one additive selected from the group consisting of graphite, aluminum powder, magnesium powder, silicon powder, calcium oxide, calcium hydroxide, magnesium oxide, and magnesium hydroxide, wherein the aggregate is present in the shaped article in an amount from about 70 to about 97% by weight.

Claim 38

Dependent Claim 20 words

A shaped article as in claim 32 further comprising a silane adhesion promoter, wherein the aggregate is alumina or silica.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-07-02	1994-01-01	1994-07-03	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-07-02	1998-01-01	1998-07-03	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-07-02	2002-01-01	2002-07-03	$7700.00	Window Closed / Lapsed

Lithium-containing resole composition for making a shaped refractory article and other hardened articles

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