Akzona Incorporated

Borden Chemical, Inc.

Kenneth B White

Keith D Stanley

James M Richmond

William J Largent

An embodiment of the present invention provides a method for improving the tensile strength of foundry cores and molds over what may be conventionally achieved. The use of acidic methylene compounds in binder compositions which include strongly alkaline phenolic resoles results in an ester curable binder that may be used to make foundry cores and molds having significantly greater tensile strengths than are achieved with prior art binders. An embodiment of the present invention provides a composition which includes a phenolic resole having a pH ranging from about 10.5 to about 13.5 and an acidic methylene compound.

Ester cured binders

A novel compound comprising a quaternary ammonium salt having the formula: ##STR1## wherein R- is an aliphatic hydrocarbon radical having a carbon chain length of from about 6 to about 18, and X.sup..crclbar. is Cl.sup..crclbar., I.sup..crclbar., Br.sup..crclbar., or OSO.sub.3 CH.sub.3.sup..crclbar.. The compound is soluble in water and/or isopropyl alcohol to form a true solution, which is clear and colorless at 70.degree. F. and which has particular utility as a fabric softening composition. The compound remains as a solution in water even at composition/water weight ratios of 75:25.

Quaternary ammonium salts useful as fabric softeners

A novel composition of matter, the quaternary ammonium salt having the formula: ##STR1## wherein X.sup..crclbar. is Cl.sup..crclbar., I.sup..crclbar., Br.sup..crclbar., or OSO.sub.3 CH.sub.3.sup..crclbar., which forms a fabric softening compound that is soluble in water and/or isopropyl alcohol to form a true solution, wherein the compound is clear and colorless at 70.degree. F. The compound remains as a solution in water even at composition/water weight ratios of 75:25.

Quaternary ammonium compounds having the general formula: ##STR1## wherein m is either 0, 1, 2, or 3; each R.sub.5 may be the same or different and are selected from the groups including straight- or branched-chain alkyl or alkenyl radicals having from 1 to 30 carbon atoms, inclusive, or a phenyl or benzyl radical; R.sub.2 is H-, a C.sub.1 to C.sub.10 straight- or brached-chain alkyl or alkenyl radical, a phenyl group, a benzyl group, or a halogenated alkyl group; R.sub.3 and R.sub.4 are different or the same and are selected from the group including H-, or a C.sub.1 to C.sub.10 straight- or branched-chain alkyl or alkenyl radical, a phenyl group, or a benzyl group, and wherein n is an integer between 0 and 30, inclusive, and methods for their manufacture are described.

Quaternary ammonium compounds and method for their manufacture

A method for the manufacture of polyisocyanurate foams which comprises blending a 'B' side with an 'A' side that includes an isocyanate. The 'B' side comprises a polyester polyol, an amine/quaternary ammonium borate ester blend, a surfactant, a blowing agent, and a metal catalyst in amounts of up to 20% by weight of the total weight of the 'B' side. The 'B' side remains a homogeneous liquid for at least one day without the need for agitation and the foam formed by this method has a friability not exceeding 30%.

Method for the manufacture of polyisocyanurate foams

A method for the manufacture of polyisocyanurate foams which comprises blending a 'B' side with an 'A' side comprising an isocyanate. The 'B' side comprises a diol, an amine/quaternary ammonium borate ester blend, a surfactant, a blowing agent, and a catalyst which is present in amounts up to about 20% of the total weight of the 'B' side. The 'B' side remains a homogeneous liquid for at least three days without the need for agitation and the foam formed by this method has a friability not exceeding 30%.

A method for the manufacture of urethane-modified polyisocyanurate foams in which an isocyanate is blended with a 'B' side comprising a polyol blend, a surfactant, a blowing agent, and a catalyst. The polyol blend comprises at least 5% (wt.) of a mixture of a polyalkoxylated amine and a polyalkoxylated quaternary ammonium borate ester, at least 40% (wt.) of a resin polyol, with any remainder being a polyether or polyester polyol. All components of the 'B' side will remain a homogeneous liquid without phase separation and without the need for agitation for at least 3 days after blending. The resin polyols are preferably moderate viscosity, aromatic polyester polyols derived from polycarbomethoxyl-substituted diphenyls, polyphenyls, and benzyl esters of the toluate family.

Polyols for urethane-modified isocyanurate foams

A method for the manufacture of urethane-modified polyisocyanurate foams in which an isocyanate is blended with a 'B' side comprising a polyol blend, a surfactant, a blowing agent, and optionally, a catalyst. The polyol blend comprises at least 5% (wt.) of a mixture of a polyalkoxylated amine and a polyalkoxylated quaternary ammonium borate ester, at least 45% (wt.) of a resin polyol, with any remainder being a polyether or polyester polyol. All components of the 'B' side will remain a homogeneous liquid without phase separation and without the need for agitation for at least 3 days and 7 days after blending.

Method for urethane-modified isocyanurate foams

A method for the manufacture of polyisocyanurate foams which comprises blending a 'B' side with an 'A' side comprising an isocyanate. The 'B' side comprises a diol, an amine/quaternary ammonium borate ester blend, a surfactant, a blowing agent, and a metal catalyst whose weight does not exceed 1.5% of the total weight of the 'B' side. The 'B' side remains a homogeneous liquid for at least seven days without the need for agitation and the foam formed by this method has a friability not exceeding 30%.

A method for the manufacture of urethane-modified polyisocyanurate foams in which an isocyanate is blended with a 'B' side comprising a polyol blend, a surfactant, a blowing agent, and a catalyst. The polyol blend comprises at least 5% (wt.) of a mixture of a polyalkoxylated amine and a polyalkoxylated quaternary ammonium borate ester, at least 40% (wt.) of a resin polyol, with any remainder being a polyether or polyester polyol. All components of the 'B' side will remain a homogeneous liquid without phase separation and without the need for agitation for at least 7 days after blending. The resin polyols are preferably moderate viscosity, aromatic polyester polyols derived from polycarbomethoxyl-substituted diphenyls, polyphenyls, and benzyl esters of the toluate family.

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Chicago, IL, United States of America

Kenneth B White