Ashland Oil, Inc.

Ashland, Inc.

Heimo J Langer

William R Dunnavant

Bruce A Gruber

Robert Bernard Fechter

Diether Koch

Thomas E Dando

John J Gardikes

William J McKillip

William R Dunnayant

Satish S Jhaveri

Steven C Akey

Ruth A Bambauer

Ruth A Dudenhoefer

Yuily M Yunovich

David A Hutchings

Robert A Grimm

Ken K Chang

Helena Twardowska

Peter E Throckmorton

Young D Kim

Gregory P Sturtz

Gary R Hysell

Kenneth R Robinson

Ralph D Martin

John F Plummer

Grant O Sedgwick

Helena J Twardowska

This invention relates to an organic foundry binder containing an alkyl resorcinol, or preferably a readily available mixture of alkyl resorcinols, and derivatives thereof. Preferably, the organic foundry binder is a furan binder. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and allowing it to cure to form a workable foundry shape. The invention also relates to the preparation of metal castings using the foundry shapes and the metal castings prepared with the foundry shapes.

Foundry binder systems containing an alkyl resorcinol and their use

This invention relates to benzylic ether phenolic resole resins prepared in a sealed reaction vessel and their uses. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Benzylic ether phenolic resole resins and their uses

This invention relates to a process for preparing benzylic ether phenolic resole resins in a sealed reaction vessel. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Process for preparing benzylic ether phenolic resole resins

This invention relates to benzylic ether phenolic resole resins prepared in a sealed reaction vessel. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Benzylic ether phenolic resole resins

This invention relates to inorganic no-bake foundry binder systems and their uses. The binder systems comprise as separate components: (A) mono-aluminum phosphate in an aqueous solution containing specified phosphoric acids, and (B) magnesium oxide; and certain specified zinc compounds in either the Component A, Component B or both. The components of the binder system react when they are mixed with a foundry aggregate to prepare foundry mixes which are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

Inorganic foundry binder systems and their uses

This invention relates to heat curable foundry binder systems comprising as separate components (a) a caustic solution of an alkali silicate and (b) hydrated aluminum silicate. The solution is mixed with sand to form a foundry mix. The resulting foundry mix is shaped and heated at an elevated temperature to form a cured foundry shape. Heat is applied by warm air, baking in an oven, microwave, or preferably from hot-box equipment.

Heat curable foundry binder systems

This invention relates to heat-cured foundry binders comprising in admixture (1) a source of soluble silica, and (2) a source of soluble alumina, such that the source of silica, source of alumina, or both contain an alkali metal. The binder components form a saturated solution when they are mixed with an aggregate. The resulting mix is shaped and heated at an elevated temperature to form a cured foundry shape. Heat is applied by warm air with warm-box equipment, baking in an oven, microwave, and preferably from hot-box equipment.

Heat cured foundry binders and their use

This invention relates to inorganic no-bake foundry binder systems and their uses. The binder systems comprise as separate Part A and Part B components: (A) an aqueous solution of specified phosphoric acids, and (B) a mixture comprising (1) an iron oxide selected from the group consisting of (a) ferrous oxide, (b) ferroferric oxide, and (c) mixtures thereof and (2) magnesium oxide. The binder systems are used to prepare foundry mixes which are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

Inorganic poundry binder systems and their uses

This invention relates to inorganic no-bake foundry binder systems and their uses. The binder systems comprise as separate Part A and Part B components: (A) an aqueous solution of specified phosphoric acids, and (b) a mixture comprising (1) an iron oxide selected from the group consisting of (a) ferrous oxide, (b) ferroferric oxide, and (c) mixtures thereof and (2) magnesium oxide. The binder systems are used to prepare foundry mixes which are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

This invention relates to heat curable foundry mixes and binder compositions particularly suitable for making foundry shapes by a hot box process. The binders used are aqueous basic solutions of phenolic resole resins. Salts are added to the binders or the sand to improve the tensile strength of foundry shapes made with the foundry mixes. Silicone compounds are added to the aggregate to improve the water resistance of foundry shapes made with the foundry mixes containing the binder and salt. The foundry shapes are used to prepare metal castings.

Hot box process for preparing foundry shapes with certain aqueous

Polymeric cyclopentadiene derivatives, method for preparing polymeric cyclopentadiene derivatives, and use of polymeric cyclopentadiene derivatives in curable binder compositions.

Composition, method for preparing and use thereof

Heat curable foundry mixes and binder compositions

The subject invention relates to modifiers for aqueous basic solutions of phenolic resins. The modifiers are open-chain ether alcohols or ketone alcohols. They assist in stabilizing the aqueous basic solutions of phenolic resole resins and improve the tensile strength of foundry shapes prepared from foundry mixes made with the aqueous basic solutions.

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Columbus, OH, United States of America

Heimo J Langer